Process for making multi-ply fibrous structure-containing articles

ABSTRACT

Articles, for example multi-ply fibrous structure-containing articles such as multi-ply sanitary tissue products, containing two or more fibrous structure plies, and more particularly to multi-ply articles containing two or more fibrous structure plies having a plurality of fibrous elements wherein the articles exhibit improved bulk and absorbent properties compared to known articles and methods for making same, are provided.

FIELD OF THE INVENTION

The present invention relates to a process for making multi-ply fibrousstructure-containing articles.

BACKGROUND OF THE INVENTION

Processes for making multi-ply fibrous structure-containing articles areknown. However, none of the known processes combine an embossed fibrousstructure ply such that the article exhibits a Core Height Value(MikroCAD Value) of greater than 0.60 mm and is bonded to at least oneother fibrous structure ply by a water-resistant bond.

Known process have made articles comprising fibrous structurescomprising a plurality of fibrous elements, for example filaments andfibers, one such prior art article 10 comprising a fibrous structurecomprising a plurality of fibrous elements (filaments and/or fibers) asshown in Prior Art FIG. 1 comprises a meltblown or spunbond polymericabrasive layer 12 and an absorbent layer 14, such as a wet-laid fibrousstructure, a coform fibrous structure, or an air-laid fibrous structure.However, such known articles, for example multi-ply fibrousstructure-containing articles that may exhibit embossments that resultin the multi-ply fibrous structure articles having a Core Height Value(MikroCAD Value) of greater than 0.60 mm as measured according to theSurface Texture Analysis Test Method do not exhibit the properties ofthe multi-ply fibrous structure-containing articles of the presentinvention because they are not bonded together via a water-resistantbond and therefore the height of the embossments are significantlyreduced upon wetting of the prior art articles.

Accordingly, there is a need for a process for making multi-ply fibrousstructure-containing articles such that the resulting article exhibitimproved bulk and/or absorbent properties that are consumer acceptablethat maintain sufficient bulk properties when wet during use byconsumers and/or without negatively impacting the softness and/orflexibility and/or stiffness of such articles and/or with improving thesoftness and/or flexibility and/or stiffness of such articles.

SUMMARY OF THE INVENTION

The present invention fulfills the need described above by providing aprocess for making multi-ply fibrous structure-containing articlescomprising bonding an embossed fibrous structure ply to at least oneother fibrous structure ply by a water-resistant bond such that voidvolume is formed between the bonded fibrous structure plies.

One solution to the problem identified above is a process that makes asided (for example texturally different sides and/or compositionallydifferent sides) comprises the steps of embossing a fibrous structureply, for example embossing a fibrous structure ply, for example aco-formed fibrous structure ply and/or a wet-laid fibrous structure plyand/or direct formed fibrous structure ply as described hereinafter,such that the resulting multi-ply fibrous structure-containing articleexhibits a Core Height Value (MikroCAD Value) of greater than 0.60 mmand/or greater than 0.75 mm and/or greater than 0.90 mm and/or greaterthan 1.00 mm and/or greater than 1.10 mm and/or greater than 1.20 mmand/or greater than 1.30 mm and/or greater than 1.40 mm and/or greaterthan 1.50 mm and/or greater than 1.60 mm and/or greater than 1.70 mm asmeasured according to the Surface Texture Analysis Test Method describedherein, and wherein the embossed fibrous structure ply is bonded to atleast one other fibrous structure ply, for example a non-embossedfibrous structure ply, for example a co-formed fibrous structure and/ora wet-laid fibrous structure ply and/or a directed formed fibrousstructure ply, by a water-resistant bond, such as a thermal bond, suchthat void volume is formed between the bonded fibrous structure pliessuch that the articles exhibit improved bulk and/or absorbent propertiescompared to known fibrous structure-containing articles.

It has been unexpectedly found by the inventors that by independentlycontrolling and/or designing the characteristics/properties of eachfunctional side of the multi-ply fibrous structure-containing article ofthe present invention to be different, consumers desire such multi-plyfibrous structure-containing articles compared to the known multi-plyfibrous structure-containing articles. These characteristic/propertydifferences between the two functional sides results topographic (i.e.,texture differences, thickness differences, thickness resiliency evenwhen wet) differences and/or compositional (pulp fibers (airlaid and wetlaid pulp fibers), synthetic staple fibers, filaments, for examplecontinuous filaments).

For clarity purposes, one non-limiting example of a topographicallydifferent (non-palindromic, different functional sides) multi-plyfibrous structure-containing article according to the present inventionis a multi-ply fibrous structure-containing article in which one fibrousstructure ply has been locally deformed, textured, embossed at anembossment height such that the fibrous structure ply exhibits a CoreHeight Value (MikroCAD Value) of greater than 0.60 mm and/or greaterthan 0.75 mm and/or greater than 0.90 mm and/or greater than 1.00 mmand/or greater than 1.10 mm and/or greater than 1.20 mm and/or greaterthan 1.30 mm and/or greater than 1.40 mm and/or greater than 1.50 mmand/or greater than 1.60 mm and/or greater than 1.70 mm as measuredaccording to the Surface Texture Analysis Test Method described herein,then attached to a non-deformed and/or less textured ply fibrousstructure ply, if embossed, it comprises no embossments exhibiting anembossment height such that the fibrous structure ply exhibits a CoreHeight Value (MikroCAD Value) of greater than 0.60 mm, for example lessthan 0.60 mm and/or less than 0.50 mm and/or less than 0.40 mm and/orless than 0.30 mm and/or less than 0.20 mm and/or less than 0.10 mmand/or less than 0.050 mm as measured according to the Surface TextureAnalysis Test Method described herein such that the multi-ply fibrousstructure-containing article exhibits a Core Height Difference Value(MikroCAD Difference Value) of greater than 0.50 mm and/or greater than0.55 mm and/or greater than 0.60 mm and/or greater than 0.64 mm and/orgreater than 0.75 mm and/or greater than 0.84 mm and/or greater than0.95 mm and/or greater than 1.00 mm and/or greater than 1.05 mm and/orgreater than 1.10 mm and/or greater than 1.15 mm and/or greater than1.20 mm and/or greater than 1.25 mm as measured according to the SurfaceTexture Analysis Test Method described herein. These properties hasshown to generate excellent dry and wet resiliency due to the texturedsheet being longer than the flatter sheet when bonded together at apoint that exhibits strength even when wet (a water-resistant bond, suchas a thermal bond and/or a water-resistant adhesive bond). This “durablewhen wet bond” (water-resistant bond) creates a “pucker”, facilitatingan interply void volume between two or more of the fibrous structureplies (the water-resistant bonded fibrous structure plies). Furthermore,the resiliency of the water-resistant bond between bonded fibrousstructure plies when wet is an important property/characteristic to theconsumers.

For clarity purposes, one non-limiting example of a compositionallydifferent (non-palindromic, different functional sides), for exampledifferent fibrous elements within the multi-ply fibrousstructure-containing article according to the present invention is amulti-ply fibrous structure-containing article in which one or morefibrous structure plies is comprised of filaments, airlaid pulp fibers,wetlaid pulp fibers, synthetic staple fibers, or other materials, andone or more other fibrous structure plies is comprised of differentelements.

A non-limiting example of a compositionally and topographicallydifferent (non-palindromic, different functional sides) multi-plyfibrous structure-containing article comprises different fibrouselements and different topography as exemplified in the previous twoparagraphs.

It has been shown that sided differences in texture within a multi-plyfibrous structure-containing article that exhibits a Core HeightDifference Value (MikroCAD Difference Value) of the present inventionexhibits significant consumer benefits during use. Without being boundby theory, if one side of the multi-ply fibrous structure-containingarticle (a single fibrous structure ply) has a texture, for example anembossment such that the multi-ply fibrous structure-containing articleand/or single ply fibrous structure ply making the side exhibits a CoreHeight Value (MikroCAD Value) of greater than 0.60 mm and greater asdescribed above as measured according to the Surface Texture AnalysisTest Method described herein, and the other (opposite) side of themulti-ply fibrous structure-containing article and/or single fibrousstructure ply making the side exhibits a Core Height Value (MikroCADValue) of less than than 0.60 mm and/or less as described above asmeasured according to the Surface Texture Analysis Test Method describedherein such that the multi-ply fibrous structure-containing articleexhibits a Core Height Difference Value (MikroCAD Difference Value) ofgreater than 0.50 mm Core Height Value (MikroCAD Value) and/or greateras described above as measured according to the Surface Texture AnalysisTest Method described herein. Examples of the consumer benefits achievedwith the multi-ply fibrous structure-containing article include improvedvisual appearance and consumer appeal through highly textured surfaceappearing on the outside of a roll of multi-ply fibrousstructure-containing article, and the textured side of the multi-plyfibrous structure-containing article provides a better scrub surface,while the flatter side (non-textured side and/or less textured side) ofthe multi-ply fibrous structure-containing article can be used forimproved surface drying compared to known multi-ply fibrousstructure-containing articles.

In one example of the present invention, a process for making amulti-ply fibrous structure-containing articles comprising the steps of:

-   -   a. embossing a fibrous structure ply such that the multi-ply        fibrous structure-containing article exhibits a Core Height        Value (MikroCAD Value) of greater than 0.60 mm and/or greater        than 0.75 mm and/or greater than 0.90 mm and/or greater than        1.00 mm and/or greater than 1.10 mm and/or greater than 1.20 mm        and/or greater than 1.30 mm and/or greater than 1.40 mm and/or        greater than 1.50 mm and/or greater than 1.60 mm and/or greater        than 1.70 mm as measured according to the Surface Texture        Analysis Test Method described herein to form an embossed        fibrous structure ply;    -   b. bonding the embossed fibrous structure ply by a        water-resistant bond, for example a thermal bond and/or a        water-resistant adhesive bond, in one example a thermal bond, to        at least one other fibrous structure ply, for example        non-embossed, to form a multi-ply fibrous structure-containing        article such that void volume is formed between the bonded        fibrous structure plies, is provided.

In one example the fibrous structure plies used in the process of thepresent invention are different such that the multi-ply fibrousstructure-containing article exhibits different sides.

Further, the fibrous structure plies of the multi-ply fibrousstructure-containing article may comprise a plurality of fibrouselements, for example filaments and/or fibers, wherein the articlecomprises two or more fibrous structure plies, for example two or moredifferent fibrous structure plies such that the article exhibitssidedness (one side of the article is not the same as the other side ofthe article, for example one surface of the article is not the same asthe other surface of the article), wherein at least one of the fibrousstructure plies is embossed such that at least two of the fibrousstructure plies of the article exhibit a Core Height Difference Value(MikroCAD Difference Value) of greater than 0.50 mm and/or greater than0.55 mm and/or greater than 0.60 mm and/or greater than 0.64 mm and/orgreater than 0.75 mm and/or greater than 0.84 mm and/or greater than0.95 mm and/or greater than 1.00 mm and/or greater than 1.05 mm and/orgreater than 1.10 mm and/or greater than 1.15 mm and/or greater than1.20 mm and/or greater than 1.25 mm and/or at least 1.30 mm as measuredaccording to the Surface Texture Analysis Test Method described herein,is provided.

The present invention provides a process for making novel multi-plyfibrous structure-containing articles.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross-sectional representation of an example of a prior artarticle.

FIG. 2A is a cross-sectional representation of an example of a co-formedfibrous structure web according to the present invention;

FIG. 2B is an example of a process for making the co-formed fibrousstructure web of FIG. 2A;

FIG. 3 is a cross-sectional representation of an example of an articleaccording to the present invention;

FIG. 4 is a cross-sectional representation of another example of anarticle according to the present invention;

FIG. 5 is a cross-sectional representation of another example of anarticle according to the present invention;

FIG. 6A is a cross-sectional representation of another example of afibrous structure web according to the present invention;

FIG. 6B is an example of a process for making the fibrous structure webof FIG. 6A;

FIG. 7 is a cross-sectional representation of another example of anarticle according to the present invention;

FIG. 8 is a cross-sectional representation of another example of anarticle according to the present invention;

FIG. 9A is a cross-sectional representation of another example of anarticle according to the present invention;

FIG. 9B is an example of a process for making the article according toFIG. 9A

FIG. 10 is a cross-sectional representation of another example of anarticle according to the present invention;

FIG. 11 is a cross-sectional representation of another example of anarticle according to the present invention;

FIG. 12 is a cross-sectional representation of another example of anarticle according to the present invention;

FIG. 13 is a cross-sectional representation of another example of anarticle according to the present invention;

FIG. 14A is a cross-sectional representation of another example of anarticle according to the present invention;

FIG. 14B is an example of a process for making the article of FIG. 14A;

FIG. 15 is a cross-sectional representation of another example of anarticle according to the present invention;

FIG. 16A is a cross-sectional representation of another example of anarticle according to the present invention;

FIG. 16B is an example of a process for making the article of FIG. 16A;

FIG. 17 is a cross-sectional representation of another example of anarticle according to the present invention;

FIG. 18 is a cross-sectional representation of another example of anarticle according to the present invention;

FIG. 19 is a cross-sectional representation of another example of anarticle according to the present invention;

FIG. 20A is a cross-sectional representation of another example of anarticle according to the present invention;

FIG. 20B is a cross-sectional representation of another example of anarticle according to the present invention;

FIG. 21A is a cross-sectional representation of another example of afibrous structure web according to the present invention suitable foruse in the article of FIGS. 20A and 20B;

FIG. 21B is an example of a process for making the fibrous structure webof FIG. 21A;

FIG. 22A is a cross-sectional representation of another example of anarticle according to the present invention;

FIG. 22B is a cross-sectional representation of another example of anarticle according to the present invention;

FIG. 23A is a cross-sectional representation of another example of afibrous structure web according to the present invention suitable foruse in the article of FIGS. 22A and 22B;

FIG. 23B is an example of a process for making the fibrous structure webof FIG. 23A;

FIG. 24A is a cross-sectional representation of another example of anarticle according to the present invention;

FIG. 24B is a cross-sectional representation of another example of anarticle according to the present invention;

FIG. 25A is a cross-sectional representation of another example of afibrous structure web according to the present invention suitable foruse in the article of FIGS. 24A and 24B;

FIG. 25B is an example of a process for making the fibrous structure webof FIG. 25A;

FIG. 26A is a cross-sectional representation of another example of anarticle according to the present invention;

FIG. 26B is a cross-sectional representation of another example of anarticle according to the present invention;

FIG. 27A is a cross-sectional representation of another example of afibrous structure web according to the present invention suitable foruse in the article of FIGS. 26A and 26B;

FIG. 27B is an example of a process for making the fibrous structure webof FIG. 27A;

FIG. 28A is an example of a suitable embossing apparatus for use in thepresent invention;

FIG. 28B is an exploded view of a portion of FIG. 28A;

FIG. 29A is an example of a suitable embossing process for use in thepresent invention;

FIG. 29B is an exploded view of a portion of FIG. 29A;

FIG. 29C is an exploded view of a portion of FIG. 29A;

FIG. 29D is a schematic of a multi-ply fibrous structure-containingarticle produced from the embossing process of FIG. 29A;

FIG. 30A is another example of a suitable embossing process for use inthe present invention;

FIG. 30B is an exploded view of a portion of FIG. 30A;

FIG. 30C is an exploded view of a portion of FIG. 30A;

FIG. 30D is a schematic of a multi-ply fibrous structure-containingarticle produced from the embossing process of FIG. 30A;

FIG. 31A is another example of a suitable embossing process for use inthe present invention;

FIG. 31B is an exploded view of a portion of FIG. 31A;

FIG. 31C is an exploded view of a portion of FIG. 31A;

FIG. 31D is a schematic of a multi-ply fibrous structure-containingarticle produced from the embossing process of FIG. 31A;

FIG. 32 is another example of a suitable embossing process for use inthe present invention;

FIG. 33 is another example of a suitable embossing process for use inthe present invention;

FIG. 34 is an example of a multi-ply fibrous structure-containingarticle made according to Example 1;

FIG. 35 is an example of a multi-ply fibrous structure-containingarticle made according to Example 2;

FIG. 36 is an example of a multi-ply fibrous structure-containingarticle made according to Example 3;

FIG. 37 is an example of a multi-ply fibrous structure-containingarticle madeaccording to Example 4;

FIG. 38 is an example of a multi-ply fibrous structure-containingarticle according to Example 5;

FIG. 39 is a sample setup used in the Hand Protection Test Method;

FIG. 40 is a test setup used in the Hand Protection Test Method;

FIG. 41 is an example of a sample support rack used in the HFS and VFSTest Methods;

FIG. 41A is a cross-sectional view of the sample support rack of FIG.41;

FIG. 42 is an example of a sample support rack cover used in the HFS andVFS Test Methods;

FIG. 42A is a cross-sectional view of the sample support rack cover ofFIG. 42; and

FIG. 43 is setup used in the Roll Firmness Test Method.

DETAILED DESCRIPTION OF THE INVENTION

“Article” as used herein means a consumer-usable structure comprisingtwo or more and/or three or more and/or four or more fibrous structureplies, which may comprise one or more and/or two or more and/or three ormore and/or four or more fibrous structure webs, according to thepresent invention. In one example the article is a dry article. Inaddition, the article may be a sanitary tissue product. A fibrousstructure ply of the present invention may comprise one or more and/ortwo or more and/or three or more different fibrous structure websselected from the group consisting of: wet-laid fibrous structure webs,air-laid fibrous structure webs, co-formed fibrous structure web,meltblown fibrous structure webs, and spunbond fibrous structure webs.In one example, a fibrous structure ply and/or an article according tothe present invention is void of a hydroentangled fibrous structure websand/or is not hydroentangled. In another example, a fibrous structureply and/or an article according to the present invention is void of acarded fibrous structure webs and/or is not carded. In addition to thefibrous structure webs, the fibrous structure plies and/or articles ofthe present invention may further comprise other solid matter, such assponges, foams, particle, such as absorbent gel materials, and mixturesthereof.

In one example, two or more fibrous structure webs may be associatedtogether to form a fibrous structure ply of the present invention.

In one example, two or more fibrous structure plies of the presentinvention may be associated together to form an article of the presentinvention.

In one example, a fibrous structure ply and/or an article of the presentinvention comprises one or more co-formed fibrous structure webs. Inaddition to the co-formed fibrous structure web, the fibrous structureply and/or the article may further comprise one or more wet-laid fibrousstructure webs, for example 100% pulp fibers or a mixture of pulp fibersand synthetic staple fibers.

In one example, a fibrous structure ply may comprise one or moreco-formed fibrous structure webs associated with one or more wet-laidfibrous structure webs, for example one or more co-formed fibrousstructure webs (with or without scrim) may be formed directly onto awet-laid fibrous structure web to associate the co-formed fibrousstructure web with the wet-laid fibrous structure web forming a fibrousstructure ply. Also in addition to the co-formed fibrous structure webwith or without one or more wet-laid fibrous structure web, the fibrousstructure ply may further comprise one or more meltblown fibrousstructure webs, which may be considered scrims on the co-formed fibrousstructure webs.

In another example, a fibrous structure ply and/or an article of thepresent invention may comprise one or more multi-fibrous element fibrousstructure webs (e.g., a fibrous structure comprising a mixture offilaments and fibers), such as a co-formed fibrous structure web, andone or more mono-fibrous element fibrous structure webs (e.g., a fibrousstructure comprising only fibers or only filaments, not a mixture offibers and filaments), such as a wet-laid fibrous structure web and/or ameltblown fibrous structure web.

In one example, at least a portion of fibrous structure plies of thepresent invention and/or the articles of the present invention exhibit abasis weight of about 150 gsm or less and/or about 100 gsm or lessand/or from about 30 gsm to about 95 gsm.

“Sanitary tissue product” as used herein means a soft, low density (i.e.<about 0.15 g/cm³) web useful as a wiping implement for post-urinary andpost-bowel movement cleaning (toilet tissue), for otorhinolaryngologicaldischarges (facial tissue), and multi-functional absorbent and cleaninguses (absorbent towels). Non-limiting examples of suitable sanitarytissue products of the present invention include paper towels, bathtissue, facial tissue, napkins, baby wipes, adult wipes, wet wipes,cleaning wipes, polishing wipes, cosmetic wipes, car care wipes, wipesthat comprise an active agent for performing a particular function,cleaning substrates for use with implements, such as a Swifter® cleaningwipe/pad. The sanitary tissue product may be convolutedly wound uponitself about a core or without a core to form a sanitary tissue productroll.

The sanitary tissue products of the present invention may exhibit abasis weight between about 10 g/m² to about 500 g/m² and/or from about15 g/m² to about 400 g/m² and/or from about 20 g/m² to about 300 g/m²and/or from about 20 g/m² to about 200 g/m² and/or from about 20 g/m² toabout 150 g/m² and/or from about 20 g/m² to about 120 g/m² and/or fromabout 20 g/m² to about 110 g/m² and/or from about 20 g/m² to about 100g/m² and/or from about 30 to 90 g/m². In addition, the sanitary tissueproduct of the present invention may exhibit a basis weight betweenabout 40 g/m² to about 500 g/m² and/or from about 50 g/m² to about 400g/m² and/or from about 55 g/m² to about 300 g/m² and/or from about 60 to200 g/m². In one example, the sanitary tissue product exhibits a basisweight of less than 100 g/m² and/or less than 80 g/m² and/or less than75 g/m² and/or less than 70 g/m² and/or less than 65 g/m² and/or lessthan 60 g/m² and/or less than 55 g/m² and/or less than 50 g/m² and/orless than 47 g/m² and/or less than 45 g/m² and/or less than 40 g/m²and/or less than 35 g/m² and/or to greater than 20 g/m² and/or greaterthan 25 g/m² and/or greater than 30 g/m² as measured according to theBasis Weight Test Method described herein.

The sanitary tissue products of the present invention may exhibit adensity (measured at 95 g/in²) of less than about 0.60 g/cm³ and/or lessthan about 0.30 g/cm³ and/or less than about 0.20 g/cm³ and/or less thanabout 0.10 g/cm³ and/or less than about 0.07 g/cm³ and/or less thanabout 0.05 g/cm³ and/or from about 0.01 g/cm³ to about 0.20 g/cm³ and/orfrom about 0.02 g/cm³ to about 0.10 g/cm³.

The sanitary tissue products of the present invention may comprisesadditives such as softening agents, temporary wet strength agents,permanent wet strength agents, bulk softening agents, silicones, wettingagents, latexes, especially surface-pattern-applied latexes, drystrength agents such as carboxymethylcellulose and starch, and othertypes of additives suitable for inclusion in and/or on sanitary tissueproducts.

“Fibrous structure ply” as used herein means a unitary structurecomprising one or more fibrous structure webs that are associated withone another, such as by compression bonding (for example by passingthrough a nip formed by two rollers), thermal bonding (for example bypassing through a nip formed by two rollers where at least one of therollers is heated to a temperature of at least about 120° C. (250° F.),microselfing, needle punching, and gear rolling, to form the unitarystructure, for example a unitary structure that exhibits sufficientintegrity to be processed with web handling equipment and/or exhibits abasis weight of at least 6 gsm and/or at least 8 gsm and/or at least 10gsm and/or at least 15 gsm and/or at least 20 gsm and/or at least 30 gsmand/or at least 40 gsm. The unitary structure may also be referred to asa ply.

“Fibrous structure web” as used herein means a structure that comprisesa plurality of fibrous elements, for example a plurality of filamentsand/or a plurality of fibers, for example pulp fibers, for example woodpulp fibers, and/or cellulose fibrous elements and/or cellulose fibers,such as pulp fibers, for example wood pulp fibers. In addition to thefibrous elements, the fibrous structures may comprise particles, such asabsorbent gel material particles. In one example, a fibrous structureaccording to the present invention means an orderly arrangement offibrous elements within a structure in order to perform a function. Inanother example, a fibrous structure according to the present inventionis a nonwoven. In one example, the fibrous structures of the presentinvention may comprise wet-laid fibrous structures, for example embossedconventional wet pressed fibrous structures, through-air-dried (TAD)fibrous structures both creped and/or uncreped, belt-creped fibrousstructures, fabric-creped fibrous structures, and combinations thereof,air-laid fibrous structures, such as thermally-bonded air-laid (TBAL)fibrous structures, melt-bonded air-laid (MBAL), latex-bonded air-laid(LBAL) fibrous structures and combinations thereof, co-formed fibrousstructures, meltblown fibrous structures, and spunbond fibrousstructures, carded fibrous structures, and combinations thereof. In oneexample, the fibrous structure is a non-hydroentangled fibrousstructure. In another example, the fibrous structure is a non-cardedfibrous structure.

In another example of the present invention, a fibrous structurecomprises a plurality of inter-entangled fibrous elements, for exampleinter-entangled filaments.

Non-limiting examples of fibrous structure plies and/or fibrousstructure webs of the present invention include paper.

The fibrous structure webs of the present invention may be homogeneousor may be layered. If layered, the fibrous structure webs may compriseat least two and/or at least three and/or at least four and/or at leastfive layers.

Any one of the fibrous structure webs may itself be a fibrous structureply in the multi-ply fibrous structure-containing article of the presentinvention if the fibrous structure web exhibits sufficient integrity tobe processed with web handling equipment and/or exhibits a basis weightof at least 6 gsm and/or at least 8 gsm and/or at least 10 gsm and/or atleast 15 gsm and/or at least 20 gsm and/or at least 30 gsm and/or atleast 40 gsm. An example of such a fibrous structure web, for example awet-laid fibrous structure web exhibiting a basis weight of at least 10gsm and/or at least 15 gsm and/or at least 20 gsm can be a fibrousstructure ply itself.

Non-limiting examples of processes for making the fibrous structure websof the present invention include known wet-laid papermaking processes,for example conventional wet-pressed (CWP) papermaking processes andthrough-air-dried (TAD), both creped TAD and uncreped TAD, papermakingprocesses, and air-laid papermaking processes. Such processes typicallyinclude steps of preparing a fiber composition in the form of a fibersuspension in a medium, either wet, more specifically aqueous medium, ordry, more specifically gaseous, i.e. with air as medium. The aqueousmedium used for wet-laid processes is oftentimes referred to as a fiberslurry. The fiber slurry is then used to deposit a plurality of thefibers onto a forming wire, fabric, or belt such that an embryonic webmaterial is formed, after which drying and/or bonding the fiberstogether results in a fibrous structure web and/or fibrous structureply. Further processing of the fibrous structure web and/or fibrousstructure ply may be carried out such as calendering, consolidating,embossing, surface treating, and the like. For example, in typicalpapermaking processes, the fibrous structure web and/or fibrousstructure ply is wound on the reel at the end of papermaking, oftenreferred to as a parent roll, and may subsequently be converted into afibrous structure ply by associating the fibrous web with one or moreother fibrous webs and/or ultimately incorporated into a multi-plyfibrous structure-containing article, such as a multi-ply sanitarytissue product, according to the present invention.

“Multi-fibrous element fibrous structure web” as used herein means afibrous structure web that comprises filaments and fibers, for example aco-formed fibrous structure web is a multi-fibrous element fibrousstructure web.

“Mono-fibrous element fibrous structure web” as used herein means afibrous structure web that comprises only fibers or filaments, forexample a wet-laid fibrous structure web or meltblown fibrous structureweb, respectively, not a mixture of fibers and filaments.

“Co-formed fibrous structure web” as used herein means that the fibrousstructure web comprises a mixture of filaments, for example meltblownfilaments, such as thermoplastic filaments, for example polypropylenefilaments, and fibers, such as pulp fibers, for example wood pulpfibers. The filaments and fibers are commingled together to form theco-formed fibrous structure web. The co-formed fibrous structure web maybe associated with one or more meltblown fibrous structure webs and/orspunbond fibrous structure webs, which form a scrim (for example at abasis weight of greater than 0.5 gsm to about 5 gsm and/or from about 1gsm to about 4 gsm and/or from about 1 gsm to about 3 gsm and/or fromabout 1.5 gsm to about 2.5 gsm, such as on one or more surfaces of theco-formed fibrous structure.

The co-formed fibrous structure web of the present invention may be madevia a co-forming process. A non-limiting example of a co-formed fibrousstructure web and a processs for making such a co-formed fibrousstructure web associated with or without a meltblown fibrous structureweb and/or spunbond fibrous structure web on one or both surfaces of theco-formed fibrous structure web and process for making is shown in FIGS.2A and 2B.

“Fibrous element” as used herein means an elongate particulate having alength greatly exceeding its average diameter, i.e. a length to averagediameter ratio of at least about 10. A fibrous element may be a filamentor a fiber. In one example, the fibrous element is a single fibrouselement rather than a yarn comprising a plurality of fibrous elements.

The fibrous elements of the present invention may be spun from polymermelt compositions via suitable spinning operations, such as meltblowingand/or spunbonding and/or they may be obtained from natural sources suchas vegetative sources, for example trees.

The fibrous elements of the present invention may be monocomponentand/or multicomponent. For example, the fibrous elements may comprisebicomponent fibers and/or filaments. The bicomponent fibers and/orfilaments may be in any form, such as side-by-side, core and sheath,islands-in-the-sea and the like.

“Filament” as used herein means an elongate particulate as describedabove that exhibits a length of greater than or equal to 5.08 cm (2 in.)and/or greater than or equal to 7.62 cm (3 in.) and/or greater than orequal to 10.16 cm (4 in.) and/or greater than or equal to 15.24 cm (6in.).

Filaments are typically considered continuous or substantiallycontinuous in nature. Filaments are relatively longer than fibers.Non-limiting examples of filaments include meltblown and/or spunbondfilaments. Non-limiting examples of polymers that can be spun intofilaments include natural polymers, such as starch, starch derivatives,cellulose, such as rayon and/or lyocell, and cellulose derivatives,hemicellulose, hemicellulose derivatives, and synthetic polymersincluding, but not limited to polyvinyl alcohol filaments and/orpolyvinyl alcohol derivative filaments, and thermoplastic polymerfilaments, such as polyesters, nylons, polyolefins such as polypropylenefilaments, polyethylene filaments, and biodegradable or compostablethermoplastic fibers such as polylactic acid filaments,polyhydroxyalkanoate filaments, polyesteramide filaments, andpolycaprolactone filaments. The filaments may be monocomponent ormulticomponent, such as bicomponent filaments.

The filaments may be made via spinning, for example via meltblowingand/or spunbonding, from a polymer, for example a thermoplastic polymer,such as polyolefin, for example polypropylene and/or polyethylene,and/or polyester. Filaments are typically considered continuous orsubstantially continuous in nature.

“Meltblowing” is a process for producing filaments directly frompolymers or resins using high-velocity air or another appropriate forceto attenuate the filaments before collecting the filaments on acollection device, such as a belt, for example a patterned belt ormolding member. In a meltblowing process the attenuation force isapplied in the form of high speed air as the material (polymer) exits adie or spinnerette.

“Spunbonding” is a process for producing filaments directly frompolymers by allowing the polymer to exit a die or spinnerette and drop apredetermined distance under the forces of flow and gravity and thenapplying a force via high velocity air or another appropriate source todraw and/or attenuate the polymer into a filament.

“Fiber” as used herein means an elongate particulate as described abovethat exhibits a length of less than 5.08 cm (2 in.) and/or less than3.81 cm (1.5 in.) and/or less than 2.54 cm (1 in.).

Fibers are typically considered discontinuous in nature. Non-limitingexamples of fibers include pulp fibers, such as wood pulp fibers, andsynthetic staple fibers such as polypropylene, polyethylene, polyester,copolymers thereof such as PET/coPET, rayon, lyocell, glass fibers andpolyvinyl alcohol fibers.

Staple fibers, in one example, may be produced by spinning a filamenttow and then cutting the tow into segments of less than 5.08 cm (2 in.)thus producing fibers; for example synthetic staple fibers.

“Pulp fibers” as used herein means fibers that have been derived fromvegetative sources, such as plants and/or trees. In one example of thepresent invention, “pulp fiber” refers to papermaking fibers. In oneexample of the present invention, a fiber may be a naturally occurringfiber, which means it is obtained from a naturally occurring source,such as a vegetative source, for example a tree and/or plant, such astrichomes. Such fibers are typically used in papermaking and areoftentimes referred to as papermaking fibers. Papermaking fibers usefulin the present invention include cellulosic fibers commonly known aswood pulp fibers. Applicable wood pulps include chemical pulps, such asKraft, sulfite, and sulfate pulps, as well as mechanical pulpsincluding, for example, groundwood, thermomechanical pulp and chemicallymodified thermomechanical pulp. Chemical pulps, however, may bepreferred since they impart a superior tactile sense of softness tofibrous structures made therefrom. Pulps derived from both deciduoustrees (hereinafter, also referred to as “hardwood”) and coniferous trees(hereinafter, also referred to as “softwood”) may be utilized. Thehardwood and softwood fibers can be blended, or alternatively, can bedeposited in layers to provide a stratified web. Also applicable to thepresent invention are fibers derived from recycled paper, which maycontain any or all of the above categories of fibers as well as othernon-fibrous polymers such as fillers, softening agents, wet and drystrength agents, and adhesives used to facilitate the originalpapermaking.

In one example, the wood pulp fibers are selected from the groupconsisting of hardwood pulp fibers, softwood pulp fibers, and mixturesthereof. The hardwood pulp fibers may be selected from the groupconsisting of: tropical hardwood pulp fibers, northern hardwood pulpfibers, and mixtures thereof. The tropical hardwood pulp fibers may beselected from the group consisting of: eucalyptus fibers, acacia fibers,and mixtures thereof. The northern hardwood pulp fibers may be selectedfrom the group consisting of: cedar fibers, maple fibers, and mixturesthereof.

In addition to the various wood pulp fibers, other cellulosic fiberssuch as cotton linters, rayon, lyocell, trichomes, seed hairs, ricestraw, wheat straw, bamboo, and bagasse fibers can be used in thisinvention. Other sources of cellulose in the form of fibers or capableof being spun into fibers include grasses and grain sources.

“Trichome” or “trichome fiber” as used herein means an epidermalattachment of a varying shape, structure and/or function of a non-seedportion of a plant. In one example, a trichome is an outgrowth of theepidermis of a non-seed portion of a plant. The outgrowth may extendfrom an epidermal cell. In one embodiment, the outgrowth is a trichomefiber. The outgrowth may be a hairlike or bristlelike outgrowth from theepidermis of a plant.

Trichome fibers are different from seed hair fibers in that they are notattached to seed portions of a plant. For example, trichome fibers,unlike seed hair fibers, are not attached to a seed or a seed podepidermis. Cotton, kapok, milkweed, and coconut coir are non-limitingexamples of seed hair fibers.

Further, trichome fibers are different from nonwood bast and/or corefibers in that they are not attached to the bast, also known as phloem,or the core, also known as xylem portions of a nonwood dicotyledonousplant stem. Non-limiting examples of plants which have been used toyield nonwood bast fibers and/or nonwood core fibers include kenaf,jute, flax, ramie and hemp.

Further trichome fibers are different from monocotyledonous plantderived fibers such as those derived from cereal straws (wheat, rye,barley, oat, etc), stalks (corn, cotton, sorghum, Hesperaloe funifera,etc.), canes (bamboo, bagasse, etc.), grasses (esparto, lemon, sabai,switchgrass, etc), since such monocotyledonous plant derived fibers arenot attached to an epidermis of a plant.

Further, trichome fibers are different from leaf fibers in that they donot originate from within the leaf structure. Sisal and abaca aresometimes liberated as leaf fibers.

Finally, trichome fibers are different from wood pulp fibers since woodpulp fibers are not outgrowths from the epidermis of a plant; namely, atree. Wood pulp fibers rather originate from the secondary xylem portionof the tree stem.

“Basis Weight” as used herein is the weight per unit area of a samplereported in lbs/3000 ft² or g/m² (gsm) and is measured according to theBasis Weight Test Method described herein.

“Machine Direction” or “MD” as used herein means the direction parallelto the flow of the fibrous structure through the fibrous structuremaking machine and/or sanitary tissue product manufacturing equipment.

“Cross Machine Direction” or “CD” as used herein means the directionparallel to the width of the fibrous structure making machine and/orsanitary tissue product manufacturing equipment and perpendicular to themachine direction.

“Embossed” as used herein with respect to an article, sanitary tissueproduct, fibrous structure ply and/or fibrous structure web, means thatan article, sanitary tissue product, fibrous structure ply and/orfibrous structure web has been subjected to a process which converts asmooth surfaced article, sanitary tissue product, fibrous structure plyand/or fibrous structure web to an out-of-plane, textured surface byreplicating a pattern on one or more emboss rolls, which form a nipthrough which the article, sanitary tissue product, fibrous structureply and/or fibrous structure web passes. Embossed does not includecreping, microcreping, fabric creping, belt creping, printing or otherprocesses, such as through-air-drying processes, that may also impart atexture and/or decorative pattern to an article, sanitary tissueproduct, fibrous structure ply and/or fibrous structure web.

“Differential density”, as used herein, means a fibrous structure plyand/or fibrous structure web that comprises one or more regions ofrelatively low fibrous element, for example fiber, density, which arereferred to as pillow regions, and one or more regions of relativelyhigh fibrous element, for example fiber, density, which are referred toas knuckle regions.

“Densified”, as used herein means a portion of a fibrous structure plyand/or fibrous structure web that is characterized by regions ofrelatively high fibrous element, e.g., fiber, density (knuckle regions).

“Non-densified”, as used herein, means a portion of a fibrous structureply and/or fibrous structure web that exhibits a lesser fibrous elementdensity, e.g., fiber, density (one or more regions of relatively lowerfibrous element, e.g., fiber, density) (pillow regions) than anotherportion (for example a knuckle region) of the fibrous structure plyand/or fibrous structure web.

“Wet textured” as used herein means that a three-dimensional (3D)patterned fibrous structure ply and/or 3D patterned fibrous structureweb comprises texture (for example a three-dimensional topography)imparted to the fibrous structure ply and/or fibrous structure ply'ssurface and/or fibrous structure web and/or fibrous structure web'ssurface during a fibrous structure web making process. In one example,in a wet-laid fibrous structure web making process, wet texture may beimparted to a fibrous structure web upon fibers and/or filaments beingcollected on a collection device that has a three-dimensional (3D)surface which imparts a 3D surface to the fibrous structure web beingformed thereon and/or being transferred to a fabric and/or belt, such asa through-air-drying fabric and/or a patterned drying belt, comprising a3D surface that imparts a 3D surface to a fibrous structure web beingformed thereon. In one example, the collection device with a 3D surfacecomprises a patterned, such as a patterned formed by a polymer or resinbeing deposited onto a base substrate, such as a fabric, in a patternedconfiguration. The wet texture imparted to a wet-laid fibrous structureweb is formed in the fibrous structure web prior to and/or during dryingof the fibrous structure web. Non-limiting examples of collectiondevices and/or fabric and/or belts suitable for imparting wet texture toa fibrous structure web include those fabrics and/or belts used infabric creping and/or belt creping processes, for example as disclosedin U.S. Pat. Nos. 7,820,008 and 7,789,995, coarse through-air-dryingfabrics as used in uncreped through-air-drying processes, andphoto-curable resin patterned through-air-drying belts, for example asdisclosed in U.S. Pat. No. 4,637,859. For purposes of the presentinvention, the collection devices used for imparting wet texture to thefibrous structure webs would be patterned to result in the fibrousstructure webs comprising a surface pattern comprising a plurality ofparallel line elements wherein at least one, two, three, or more, forexample all of the parallel line elements exhibit a non-constant widthalong the length of the parallel line elements. This is different fromnon-wet texture that is imparted to a fibrous structure web after thefibrous structure web has been dried, for example after the moisturelevel of the fibrous structure web is less than 15% and/or less than 10%and/or less than 5%. An example of non-wet texture includes embossmentsimparted to a fibrous structure ply and/or fibrous structure web byembossing rolls during converting of the fibrous structure ply and/orfibrous structure web. In one example, the fibrous structure ply and/orfibrous structure web, for example a wet-laid fibrous structure plyand/or wet-laid fibrous structure web, is a wet textured fibrousstructure ply and/or wet textured fibrous structure web.

“3D pattern” with respect to a fibrous structure ply and/or fibrousstructure ply's surface and/or fibrous structure web and/or fibrousstructure web's surface in accordance with the present invention meansherein a pattern that is present on at least one surface of the fibrousstructure ply and/or fibrous structure web. The 3D pattern texturizesthe surface of the fibrous structure ply and/or fibrous structure web,for example by providing the surface with protrusions and/ordepressions. The 3D pattern on the surface of the fibrous structure plyand/or fibrous structure web is made by making the fibrous structure webon a patterned molding member that imparts the 3D pattern to the fibrousstructure web made thereon. For example, the 3D pattern may comprise aseries of line elements, such as a series of line elements that aresubstantially oriented in the cross-machine direction of the fibrousstructure web and/or fibrous structure ply and/or sanitary tissueproduct and/or article.

In one example, a series of line elements may be arranged in a 3Dpattern selected from the group consisting of: periodic patterns,aperiodic patterns, straight line patterns, curved line patterns, wavyline patterns, snaking patterns, square line patterns, triangular linepatterns, S-wave patterns, sinusoidal line patterns, and mixturesthereof. In another example, a series of line elements may be arrangedin a regular periodic pattern or an irregular periodic pattern(aperiodic) or a non-periodic pattern.

“Distinct from” and/or “different from” as used herein means two thingsthat exhibit different properties and/or levels of materials, forexample different by 0.5 and/or 1 and/or 2 and/or 3 and/or 5 and/or 10units and/or different by 1% and/or 3% and/or 5% and/or 10% and/or 20%,different materials, and/or different average fiber diameters.

“Textured pattern” as used herein means a pattern, for example a surfacepattern, such as a three-dimensional (3D) surface pattern present on asurface of the fibrous structure and/or on a surface of a componentmaking up the fibrous structure.

“Fibrous Structure Ply Basis Weight” and/or “Multi-ply FibrousStructure-containing Article Basis Weight” and/or “Fibrous Structure WebBasis Weight” and/or “Sanitary Tissue Product Basis Weight” as usedherein is the weight per unit area of a sample reported in lbs/3000 ft²or g/m².

“Ply” as used herein means an individual, integral fibrous structure plythat is suitable as a single ply fibrous structure article and/or isincorporated into a multi-ply fibrous structure-containing article.

“Plies” as used herein means two or more individual, integral fibrousstructure plies disposed in a substantially contiguous, face-to-facerelationship with one another, forming a multi-ply fibrousstructure-containing article, for example a multi-ply sanitary tissueproduct. It is also contemplated that an individual, integral fibrousstructure ply can effectively form a multi-ply sanitary tissue product,for example, by being folded on itself.

“Common Intensive Property” as used herein means an intensive propertypossessed by more than one region within a fibrous structure web and/orfibrous structure ply. Such intensive properties of the fibrousstructure web and/or fibrous structure ply include, without limitation,density, basis weight, thickness, and combinations thereof. For example,if density is a common intensive property of two or more differentregions, a value of the density in one region can differ from a value ofthe density in one or more other regions. Regions (such as, for example,a first region and a second region and/or a continuous network regionand at least one of a plurality of discrete zones) are identifiableareas visually discernible and/or visually distinguishable from oneanother by distinct intensive properties.

“X,” “Y,” and “Z” designate a conventional system of Cartesiancoordinates, wherein mutually perpendicular coordinates “X” and “Y”define a reference X-Y plane, and “Z” defines an orthogonal to the X-Yplane. “Z-direction” designates any direction perpendicular to the X-Yplane. Analogously, the term “Z-dimension” means a dimension, distance,or parameter measured parallel to the Z-direction. When an element, suchas, for example, a molding member curves or otherwise deplanes, the X-Yplane follows the configuration of the element.

“Substantially continuous” or “continuous” region refers to an areawithin which one can connect any two points by an uninterrupted linerunning entirely within that area throughout the line's length. That is,the substantially continuous region has a substantial “continuity” inall directions parallel to the first plane and is terminated only atedges of that region. The term “substantially,” in conjunction withcontinuous, is intended to indicate that while an absolute continuity ispreferred, minor deviations from the absolute continuity may betolerable as long as those deviations do not appreciably affect theperformance of the fibrous structure (or a molding member) as designedand intended.

“Substantially semi-continuous” or “semi-continuous” region refers anarea which has “continuity” in all, but at least one, directionsparallel to the first plane, and in which area one cannot connect anytwo points by an uninterrupted line running entirely within that areathroughout the line's length. The semi-continuous framework may havecontinuity only in one direction parallel to the first plane. By analogywith the continuous region, described above, while an absolutecontinuity in all, but at least one, directions is preferred, minordeviations from such a continuity may be tolerable as long as thosedeviations do not appreciably affect the performance of the fibrousstructure.

“Discontinuous” or “discrete” regions or zones refer to discrete, andseparated from one another areas or zones that are discontinuous in alldirections parallel to the first plane.

“Molding member” is a structural element that can be used as a supportfor the mixture of fibrous elements that can be deposited thereon duringa process of making a fibrous structure web, and as a forming unit toform (or “mold”) a desired microscopical geometry of a fibrous structureweb. The molding member may comprise any element that has the ability toimpart a three-dimensional pattern to the fibrous structure web beingproduced thereon, and includes, without limitation, a stationary plate,a belt, a cylinder/roll, a woven fabric, and a band.

“Water-resistant” and/or “water-insoluble” as used herein with respectto a bond means that the bond remains, for example retains itsintended/desired bonding function, after being saturated by water. Inone example, a water-resistant bond may comprise a thermal bond createdby heat and/or heat and pressure. In another example, a water-resistantbond may comprise a water-resistant adhesive bond created by awater-resistant adhesive.

As used herein, the articles “a” and “an” when used herein, for example,“an anionic surfactant” or “a fiber” is understood to mean one or moreof the material that is claimed or described.

All percentages and ratios are calculated by weight unless otherwiseindicated. All percentages and ratios are calculated based on the totalcomposition unless otherwise indicated.

Unless otherwise noted, all component or composition levels are inreference to the active level of that component or composition, and areexclusive of impurities, for example, residual solvents or by-products,which may be present in commercially available sources.

Multi-Ply Fibrous Structure-Containing Article

A multi-ply fibrous structure-containing article of the presentinvention comprises two or more and/or three or more and/or four or morefibrous structure plies, which comprise one or more fibrous structurewebs, wherein at least one of the fibrous structure plies is embossedwith embossments, for example embossments that exhibit an embossmentheight such that the multi-ply fibrous structure-containing articleexhibits a Core Height Value (MikroCAD Value) of greater than 0.60 mmand/or greater than 0.75 mm and/or greater than 0.90 mm and/or greaterthan 1.00 mm and/or greater than 1.10 mm and/or greater than 1.20 mmand/or greater than 1.30 mm and/or greater than 1.40 mm and/or greaterthan 1.50 mm and/or greater than 1.60 mm and/or greater than 1.70 mm asmeasured according to the Surface Texture Analysis Test Method describedherein, wherein the embossed fibrous structure ply is bonded to at leastone other fibrous structure ply via one or more and/or two or moreand/or a plurality of water-resistant bonds (for example thermal bondsand/or water-resistant adhesive bonds) such that a void volume iscreated between the two fibrous structure plies at the embossments andsuch that the articles exhibit improved bulk and/or absorbent propertiescompared to known fibrous structure-containing articles such that themulti-ply fibrous structure-containing article exhibits improved bulkand/or absorbency properties compared to existing fibrous structuresand/or multi-ply fibrous structure-containing articles, according to thepresent invention.

It has unexpectedly been found that the arrangement of the fibrousstructure plies, wherein at least one of the fibrous structure plies isembossed and bonded via a water-resistant bond results in the multi-plyfibrous structure-containing article of the present invention exhibitingnovel properties, such as bulk and/or absorbent properties withoutnegatively impacting the softness and/or flexibility and/or stiffness ofthe multi-ply fibrous structure-containing articles.

In one example, the multi-ply fibrous structure-containing articles ofthe present invention may comprise different combinations of fibrousstructure plies comprising different types and/or different mixtures offibrous elements. For example, the two or more fibrous structure pliesof the multi-ply fibrous structure-containing articles of the presentinvention may comprise different combinations (associations) of wet-laidfibrous structure plies and/or wet-laid fibrous structure webs, forexample 100% by weight of fibers, such as pulp fibers, for example woodpulp fibers (e.g., cellulosic wood pulp fibers) and co-formed fibrousstructure plies and/or co-formed fibrous structure webs, for example amixture of filaments and fibers, such as polypropylene filaments andpulp fibers, such as wood pulp fibers (e.g., cellulosic wood pulpfibers), which allows for the creation of both wet and dry bulk, whilemaintaining a soft and/or flexibility and/or non-stiff sheet. Thisunique combination of properties is afforded, in this case, by the useof the co-formed fibrous structure ply and/or co-formed fibrousstructure web, in which continuous filaments are combined with fibers ina way that the resultant bulk density of the co-formed fibrous structureply and/or co-formed fibrous structure web is very low. This low bulkdensity is maintained even when wet due the lack of collapse of thefibrous structure ply and/or fibrous structure web, as the continuousfilaments are not subject to water induced collapse. In contrast, suchbulk in wet-laid fibrous structure plies and/or wet-laid fibrousstructure webs is created via hydrogen bonding of the fibers within thewet-laid fibrous structure ply and/or wet-laid fibrous structure web,which collapse if dry forming, such as embossing and/or microselfing, isused to create a soft fibrous structure ply with dry bulk (resulting inlow wet bulk), or will be stiff if wet forming, such as forming thewet-laid fibrous structure web on a molding member and/or subjecting thewet-laid fibrous structure web to wet microcontraction during forming,is used to create a dry bulk that is resilient when wet.

In another example, the multi-ply fibrous structure-containing articlesof the present invention allow for the optimization of different fibrousstructure plies and/or fibrous structure webs for differentcharacteristics and/or properties. One example of this is how a very lowdensity, high bulk co-formed fibrous structure ply and/or co-formedfibrous structure web that is strong can be placed with a wet formed,high bulk wet-laid fibrous structure ply and/or wet-laid fibrousstructure web that is very absorbent. The resultant fibrous structureply (if direct formed, which as used herein means where one fibrousstructure web comprising fibrous elements, for example one fibrousstructure web comprising fibers and filaments, such as a coform fibrousstructure web, is deposited/spun onto another fibrous structure web, forexample a wet-laid fibrous structure web, such as a paper web) and/ormulti-ply fibrous structure-containing article is one which is bothhighly absorbent, very compressible, and able to spring back aftercompression. This results in a spongelike article which is resilientunder compression yet highly absorbent like a paper towel. The resultantfibrous structure ply (if direct formed) and/or multi-ply fibrousstructure-containing article exhibits high bulk values when dry, arecompressible under load and rebound when the load is relieved.Additionally, the resultant fibrous structure ply (if direct formed)and/or multi-ply fibrous structure-containing article exhibits highbulk, compressibility, and recovery when wet, due to the wet formednature of the wet-laid fibrous structure ply and/or wet-laid fibrousstructure web and the co-formed fibrous structure ply and/or co-formedfibrous structure web, which is impervious to wet collapse.

In another example, the multi-ply fibrous structure-containing articlesof the present invention exhibit very high sheet and/or roll bulkwithout negatively impacting softness. This high bulk can be achievedthrough multiple inner fibrous structure plies and/or fibrous structurewebs, with the interior fibrous structure plies and/or fibrous structurewebs comprised of high loft, pin-holed wet-laid fibrous structure pliesand/or wet-laid fibrous structure webs. Co-formed fibrous structureplies and/or co-formed fibrous structure webs, which contain continuous,thermoplastic filaments and pulp fibers, enable the use of high loftwet-laid fibrous structure plies and/or wet-laid fibrous structure websbecause the filaments of the co-formed fibrous structure plies and/orco-formed fibrous structure webs are used for strength (especially whenwet). Furthermore, the commingled nature of the filaments and fiberswithin the co-formed fibrous structure plies and/or co-formed fibrousstructure webs allows for very high bulk fibrous structure plies and/orfibrous structure webs that are both absorbent and soft, as individualfibers are commingled within a network of continuous filaments.Multi-ply fibrous structure-containing articles like these are verydifficult to make via other technologies such as solely wet-laidtechnology due to the fact that the fibers, such as pulp fibers, mustimpart strength and bulk and absorbency. These different demands in thepast have caused product developers to optimize for some attributes atthe expense of others.

In still another example, the multi-ply fibrous structure-containingarticles of the present invention exhibit very high absorbencies withoutcompromising softness of the article. This is achieved through theheterogenous composition of the multi-ply fibrous structure article;namely, the combination of at least two different fibrous structureplies, for example at least fibrous structure ply comprising a co-formedfibrous structure web and at least one other fibrous structure plycomprising a wet-laid fibrous structure web. To allow for highabsorbencies, wet-laid fibrous structure web making process choices suchas fiber furnish mix, fiber refining levels, and molding member, forexample belt design upon which the wet-laid fibrous structure web isformed, can be chosen to create a lofty, high absorbent capacitywet-laid fibrous structure web and/or wet-laid fibrous structure plythat is soft and low in strength. The filaments, for examplepolypropylene filaments, present in the co-formed fibrous structure weband/or co-formed fibrous structure ply is relied upon to deliver thestrength of the multi-ply fibrous structure-containing article, whilestill being soft and/or flexible and/or non-stiff both wet and dry.Additionally, the interspersion of fibers, for example pulp fibers, withthe filaments within the co-formed fibrous structure web and/orco-formed fibrous structure ply adds to the soft, velvet-like hand feelof the multi-ply fibrous structure-containing article.

In yet another example, the multi-ply fibrous structure-containingarticles of the present invention exhibit very high absorbencies withoutcompromising strength of the article. This is achieved through theheterogenous composition of the multi-ply fibrous structure-containingarticle; namely, the combination of at least two different fibrousstructure plies at least one of which is embossed such that themulti-ply fibrous structure-containing article exhibits the improvedbulk and absorbency properties. In one example, at least one of thefibrous structure plies comprises a co-formed fibrous structure weband/or co-formed fibrous structure ply and at least one other fibrousstructure ply comprises a wet-laid fibrous structure web and/or wet-laidfibrous structure ply. The wet-laid structure web and/or wet-laidfibrous structure ply can be optimized for high absorbent capacitiesand/or rates without having to compromise to maintain strength. To allowfor high absorbencies, wet-laid fibrous structure web making processchoices such as fiber furnish mix, fiber refining levels, and moldingmember, for example belt design upon which the wet-laid fibrousstructure web is formed, can be chosen to create a lofty, high absorbentcapacity wet-laid fibrous structure web and/or wet-laid fibrousstructure ply that is soft and low in strength. The filaments, forexample polypropylene filaments, present in the co-formed fibrousstructure web and/or co-formed fibrous structure ply is relied upon todeliver the strength of the multi-ply fibrous structure-containingarticle, while still being soft and/or flexible and/or non-stiff bothwet and dry. Additionally, the interspersion of fibers, for example pulpfibers, with the filaments within the co-formed fibrous structure weband/or co-formed fibrous structure ply adds to the soft, velvet-likehand feel of the multi-ply fibrous structure-containing article.

In another example, the multi-ply fibrous structure-containing articlesof the present invention exhibit high absorbent capacity while stillmaintaining hand protection. This can be achieved by tailoring thedensity, capillary pressure, and absorbent capacity of the differentfibrous structure plies within the multi-ply fibrousstructure-containing article. In one example, high density and capillarypressure wet-laid fibrous structure plies and/or wet-laid fibrousstructure webs on one or both of the exterior surfaces of the multi-plyfibrous structure-containing article allow for rapid redistribution ofwater on a surface of the multi-ply fibrous structure-containingarticle, while lower density fibrous structure plies and/or fibrousstructure webs, such as co-formed fibrous structure plies and/orco-formed fibrous structure webs, in the interior of the multi-plyfibrous structure-containing article creates storage capacity. Inanother example, thin, low density fibrous structure plies and/orfibrous structure webs, such as co-formed fibrous structure plies and/orco-formed fibrous structure webs, on one or more of the exteriorsurfaces of the multi-ply fibrous structure-containing article allow forrapid acquisition of water by the inner, more dense, high capillarypressure fibrous structure plies and/or fibrous structure webs, such aswet-laid fibrous structure plies and/or wet-laid fibrous structure webs,whose high capillary pressure structures will redistribute the water inthe multi-ply fibrous structure-containing article and not give it backto the exterior surfaces of the multi-ply fibrous structure-containingarticle.

In still another example, the multi-ply fibrous structure-containingarticles of the present invention exhibit high bulk/low density withoutimpacting the overall opacity of the multi-ply fibrousstructure-containing articles. This can be achieved by the combining ofa differential density wet-laid fibrous structure ply and/or wet-laidfibrous structure web, which have been wet formed such that relativelylow density regions and relatively high density regions are formed inthe wet-laid fibrous structure ply and/or wet-laid fibrous structureweb, to the extent that the low density regions of the wet-laid fibrousstructure ply and/or wet-laid fibrous structure web have very low basisweight, to the point of making pinholes. This is normally undesirable inwet-laid fibrous structure plies and/or wet-laid fibrous structure websand/or wet-laid fibrous structure making processes, as the pinholes aredetrimental to strength as well as opacity. When this wet-laid fibrousstructure ply and/or wet-laid fibrous structure web is combined withanother fibrous structure ply and/or fibrous structure web, such as aco-formed fibrous structure ply and/or co-formed fibrous structure web,the opacity significantly increases, creating a low density and highopacity multi-ply fibrous structure-containing article.

In yet another example, the multi-ply fibrous structure-containingarticles of the present invention are very reopenable while stillmaintaining consumer acceptable absorbent properties. This is achievedthrough the combination of two or more different fibrous structure pliesat least one of which is embossed with one or more, such as a pluralityof embossments that are bonded together, for example on two or moresides of an embossment via a water-resistant bond, such as a thermalbond and/or a water-resistant adhesive bond and/or fibrous structurewebs, such as a fibrous structure ply and/or fibrous structure webcomprising filaments and/or a mixture of filaments and fibers, andwet-laid fibrous structure ply and/or wet-laid fibrous structure web. Inone example, low basis weight filament-containing fibrous structureplies and/or fibrous structure webs, such as scrims of filaments, forexample scrims of polypropylene filaments, are arranged on one or moreof the exterior surfaces of the multi-ply fibrous structure-containingarticles, which in turn further comprises one or more inner fibrousstructure plies and/or fibrous structure webs comprising wet-laidfibrous structure plies and/or wet-laid fibrous structure webs andco-formed fibrous structure plies and/or co-formed fibrous structurewebs. This combination of materials creates a multi-ply fibrousstructure-containing article exhibits very high bulk absorbency and atthe same time exhibits high wet resiliency, allowing it to be easilyreopened during use, especially after being wetted.

In still another example, the multi-ply fibrous structure-containingarticles of the present invention exhibit both high absorbent capacityand high surface drying properties. This combination is achieved throughthe combination of two or more different fibrous structure plies atleast one of which is embossed that exhibit different capillarypressures. One example of such a multi-ply fibrous structure-containingarticle that exhibits this characteristic is a multi-ply fibrousstructure-containing article that has at least one fibrous structure plycomprising one or more wet-laid fibrous structure plies and/or wet-laidfibrous structure webs on one or more exterior surfaces of the multi-plyfibrous structure-containing article, along with at least one fibrousstructure ply comprising a co-formed fibrous structure ply and/orco-formed fibrous structure web as one or more inner fibrous structureplies and/or fibrous structure webs within the multi-ply fibrousstructure-containing article. This low density co-formed fibrousstructure ply and/or co-formed fibrous structure web core of themulti-ply fibrous structure-containing article creates large absorbentcapacity, while the wet-laid fibrous structure ply and/or wet-laidfibrous structure web on the outside of the multi-ply fibrousstructure-containing article allows for consumer acceptable surfacedrying.

In even yet another example, the multi-ply fibrous structure-containingarticles of the present invention exhibit both high wet bulk and highsurface drying properties. This combination is achieved through thecombination of two or more different fibrous structure plies at leastone of which is embossed that exhibit high capillary pressure withfibrous structure plies and/or fibrous structure webs that exhibit highbulk when wet. One example of such a multi-ply fibrousstructure-containing article that exhibits these characteristic is onethat has at least one fibrous structure ply comprising one or morewet-laid fibrous structure plies and/or wet-laid fibrous structure webson one or more exterior surfaces of a multi-ply fibrousstructure-containing article, along with at least one fibrous structureply comprising a co-formed fibrous structure ply and/or co-formedfibrous structure web in the center of the multi-ply fibrousstructure-containing article. The co-formed fibrous structure ply and/orco-formed fibrous structure web core does not collapse when wetted,while the wet-laid fibrous structure ply and/or wet-laid fibrousstructure web on the outside of the multi-ply fibrousstructure-containing article allows for consumer acceptable surfacedrying.

Non-limiting examples of articles of the present invention are describedbelow in more detail.

In one example, as shown in FIG. 3, a multi-ply fibrousstructure-containing article 20 of the present invention comprises threefibrous structure plies: 1) a first fibrous structure ply an example ofwhich is shown in FIGS. 2A and 2B comprising a co-formed fibrousstructure web 22 (a multi-fibrous element fibrous structure web)associated with two meltblown fibrous structure webs 24 (mono-fibrouselement fibrous structure webs) in this case but in another examplethere may just be one meltblown fibrous structure web 24 on one surfaceof the co-formed fibrous structure web 22, which function as scrims onopposite surfaces of the co-formed fibrous structure web 22, 2) a secondfibrous structure ply an example of which is shown in FIGS. 2A and 2Bcomprising a co-formed fibrous structure web 22 (a multi-fibrous elementfibrous structure web) associated with two meltblown fibrous structurewebs 24 (mono-fibrous element fibrous structure webs), which function asscrims on opposite surfaces of the co-formed fibrous structure web 22,and 3) a third fibrous structure ply comprising a wet-laid fibrousstructure web 26 (a mono-fibrous element fibrous structure web), forexample a textured fibrous structure web, for example a texturedwet-laid fibrous structure web, such as a 3D patterned wet-laid fibrousstructure web, positioned between and associated with at least oneand/or both of the first and second fibrous structure plies, theco-formed fibrous structure plies. The three fibrous structure plies maybe associated with each other in one operation or in multipleoperations, such as by combining two of the fibrous structure pliesfirst and then combining the remaining fibrous structure ply with thealready combined fibrous structure plies. The resulting multi-plyfibrous structure-containing article exhibits a thickness (caliper) “T”.In one example, the multi-ply fibrous structure-containing article 20shown in FIG. 3 is made by combining the pre-formed fibrous structureplies.

In one example, as shown in FIG. 4, a multi-ply fibrousstructure-containing article 20 of the present invention comprises fourfibrous structure plies similar to the a multi-ply fibrousstructure-containing article shown in FIG. 3 above: 1) a first fibrousstructure ply an example of which is shown in FIGS. 2A and 2B comprisinga co-formed fibrous structure web 22 (a multi-fibrous element fibrousstructure web) associated with two meltblown fibrous structure webs 24(mono-fibrous element fibrous structure webs) in this case but inanother example there may just be one meltblown fibrous structure web 24on one surface of the co-formed fibrous structure web 22, which functionas scrims on opposite surfaces of the co-formed fibrous structure web22, 2) a second fibrous structure ply an example of which is shown inFIGS. 2A and 2B comprising a co-formed fibrous structure web 22 (amulti-fibrous element fibrous structure web) associated with twomeltblown fibrous structure webs 24 (mono-fibrous element fibrousstructures) in this case but in another example there may just be onemeltblown fibrous structure web 24 on one surface of the co-formedfibrous structure web 22, which function as scrims on opposite surfacesof the co-formed fibrous structure web 22, and 3) third and fourthfibrous structure plies comprising wet-laid fibrous structure webs 26,(mono-fibrous element fibrous structure webs), which may be the same ordifferent from one another, for example a textured wet-laid fibrousstructure web, such as a 3D patterned wet-laid fibrous structure web,positioned between and associated with at least one and/or both of thefirst and second fibrous plies. All four of the fibrous structure pliesmay be associated with each other in one operation or in multipleoperations, such as by combining two or three of the fibrous structureplies first and then combining the remaining fibrous structure plieswith the already combined fibrous structure plies. In one example, themulti-ply fibrous structure-containing article 20 shown in FIG. 4 ismade by combining the pre-formed fibrous structure plies.

In one example, as shown in FIG. 5, a multi-ply fibrousstructure-containing article 20 of the present invention comprises twofibrous structure plies): 1) a first fibrous structure ply an example ofwhich is shown in FIGS. 2A and 2B comprising a co-formed fibrousstructure web 22 (multi-fibrous element fibrous structure web)associated with two meltblown fibrous structure webs 24 (mono-fibrouselement fibrous structures) in this case but in another example theremay just be one meltblown fibrous structure web 24 on one surface of theco-formed fibrous structure web 22, which function as scrims on oppositesurfaces of the co-formed fibrous structure web 22, and 2) a secondfibrous structure ply an example of which is shown in FIGS. 6A and 6Bcomprising a co-formed fibrous structure web 22 (multi-fibrous elementfibrous structure web associated with one meltblown fibrous structureweb 24 (mono-fibrous element fibrous structure web) on one surface ofthe co-formed fibrous structure web 22 and a wet-laid fibrous structureweb 26 (a mono-fibrous element fibrous structure web), for exampledirect formed on the wet-laid fibrous structure web, which functions asa scrim, for example a textured wet-laid fibrous structure web, such asa 3D patterned wet-laid fibrous structure web on the opposite surface ofthe co-formed fibrous structure web 22. The wet-laid fibrous structureweb 26 may be further associated with a meltblown fibrous structure web24 (mono-fibrous element fibrous structure) on the wet-laid fibrousstructure web's surface opposite the co-formed fibrous structure web 22.The fibrous structure plies may be associated with each other in oneoperation, such as by combining the two fibrous structure plies suchthat the wet-laid fibrous structure web 26 is positioned between the twoco-formed fibrous structure webs 22 in the multi-ply fibrousstructure-containing article 20. In one example, the multi-ply fibrousstructure-containing article 20 shown in FIG. 5 is made by combining thepre-formed fibrous structure plies.

In one example, as shown in FIG. 7, a multi-ply fibrousstructure-containing article 20 of the present invention comprises twofibrous structure plies: 1) first and second fibrous structure pliesexamples of which are shown in FIGS. 6A and 6B comprising a co-formedfibrous structure web 22 (multi-fibrous element fibrous structure webassociated with one meltblown fibrous structure web 24 (mono-fibrouselement fibrous structure web) on one surface of the co-formed fibrousstructure web 22 and a wet-laid fibrous structure web 26 (a mono-fibrouselement fibrous structure web), for example direct formed on thewet-laid fibrous structure web, which functions as a scrim, for examplea textured wet-laid fibrous structure web, such as a 3D patternedwet-laid fibrous structure web on the opposite surface of the co-formedfibrous structure web 22. The wet-laid fibrous structure web 26 may befurther associated with a meltblown fibrous structure web 24(mono-fibrous element fibrous structure web) on the wet-laid fibrousstructure web's surface opposite the co-formed fibrous structure web 22.The fibrous structure plies may be associated with each other in oneoperation, such as by combining the two fibrous structure plies suchthat the wet-laid fibrous structure webs 26 are positioned between thetwo co-formed fibrous structure webs 22 in the multi-ply fibrousstructure-containing article 20. In one example, the multi-ply fibrousstructure-containing article 20 shown in FIG. 7 is made by combining thepre-formed fibrous structure plies.

In one example, as shown in FIG. 8, an example of a fibrous structureply an example of which is shown in FIGS. 9A and 9B comprising awet-laid fibrous structure web 26, such as a textured wet-laid fibrousstructure web, (mono-fibrous element fibrous structure web) associatedwith two meltblown fibrous structure webs 24 (mono-fibrous elementfibrous structure webs) in this case but in another example there mayjust be one meltblown fibrous structure web 24 on one surface of theco-formed fibrous structure web 22, which function as scrims on oppositesurfaces of the wet-laid fibrous structure web 26 may be used in themulti-ply fibrous structure-containing article 20 of the presentinvention.

In one example, as shown in FIG. 10, a multi-ply fibrousstructure-containing article 20 of the present invention comprises twostructure plies): 1) first and second fibrous structure plies examplesof which are shown in FIGS. 9A and 9B comprising a wet-laid fibrousstructure web 26, which may be the same or different from one another,such as a textured wet-laid fibrous structure web, (mono-fibrous elementfibrous structure web) associated with two meltblown fibrous structurewebs 24 (mono-fibrous element fibrous structure webs) in this case butin another example there may just be one meltblown fibrous structure web24 on one surface of the co-formed fibrous structure web 22, whichfunction as scrims on opposite surfaces of the wet-laid fibrousstructure web 26. In one example, the multi-ply fibrousstructure-containing article 20 shown in FIG. 10 is made by combiningthe pre-formed fibrous structure plies.

In one example, as shown in FIG. 11, a multi-ply fibrousstructure-containing article 20 of the present invention comprises twofibrous structure plies: 1) a first fibrous structure ply an example ofwhich is shown in FIGS. 9A and 9B comprising a wet-laid fibrousstructure web 26, such as a textured wet-laid fibrous structure web,(mono-fibrous element fibrous structure) associated with two meltblownfibrous structure webs 24 (mono-fibrous element fibrous structure webs)in this case but in another example there may just be one meltblownfibrous structure web 24 on one surface of the co-formed fibrousstructure web 22, which function as scrims on opposite surfaces of thewet-laid fibrous structure web 26, and 2) a second fibrous structure plyan example of which is shown in FIGS. 6A and 6B comprising a co-formedfibrous structure web 22 (multi-fibrous element fibrous structure web)associated with one meltblown fibrous structure web 24 (mono-fibrouselement fibrous structure web) on one surface of the co-formed fibrousstructure web 22 and a wet-laid fibrous structure web 26 (a mono-fibrouselement fibrous structure web), for example direct formed on thewet-laid fibrous structure web, which functions as a scrim, for examplea textured wet-laid fibrous structure web, such as a 3D patternedwet-laid fibrous structure web on the opposite surface of the co-formedfibrous structure web 22. The wet-laid fibrous structure web 26 may befurther associated with a meltblown fibrous structure web 24(mono-fibrous element fibrous structure web) on the wet-laid fibrousstructure web's surface opposite the co-formed fibrous structure web 22.The fibrous structure plies may be associated with each other in oneoperation, such as by combining the two fibrous structure plies suchthat the wet-laid fibrous structure webs 26 are positioned as shown inFIG. 11. In one example, the multi-ply fibrous structure-containingarticle 20 shown in FIG. 11 is made by combining the pre-formed fibrousstructure plies.

In one example, as shown in FIG. 12, a multi-ply fibrousstructure-containing article 20 of the present invention comprises twofibrous structure plies: 1) a first fibrous structure ply an example ofwhich is shown in FIGS. 9A and 9B comprising a wet-laid fibrousstructure web 26, such as a textured wet-laid fibrous structure web,(mono-fibrous element fibrous structure web) associated with twomeltblown fibrous structure webs 24 (mono-fibrous element fibrousstructure webs) in this case but in another example there may just beone meltblown fibrous structure web 24 on one surface of the co-formedfibrous structure web 22, which function as scrims on opposite surfacesof the wet-laid fibrous structure web 26, and 2) a second fibrousstructure ply an example of which is shown in FIGS. 2A and 2B comprisinga co-formed fibrous structure web 22 (multi-fibrous element fibrousstructure web) associated with two meltblown fibrous structure webs 24(mono-fibrous element fibrous structures), which function as scrims onopposite surfaces of the co-formed fibrous structure web 22. The fibrousstructure plies may be associated with each other in one operation, suchas by combining the two fibrous structure plies as shown in FIG. 12. Inone example, the multi-ply fibrous structure-containing article 20 shownin FIG. 12 is made by combining the pre-formed fibrous structure plies.

In one example, as shown in FIG. 13, an example of a fibrous structureply an example of which is shown in FIGS. 14A and 14B comprising aco-formed fibrous structure web 22 (multi-fibrous element fibrousstructure web) associated with one meltblown fibrous structure web 24(mono-fibrous element fibrous structure web) on one surface of theco-formed fibrous structure web 22 and a wet-laid fibrous structure web26 (a mono-fibrous element fibrous structure web), for example directformed on the wet-laid fibrous structure web, which functions as ascrim, for example a textured wet-laid fibrous structure web, such as a3D patterned wet-laid fibrous structure web on the opposite surface ofthe co-formed fibrous structure web 22. The wet-laid fibrous structureweb 26 may be further associated with another co-formed fibrousstructure web 22, for example direct formed on the wet-laid fibrousstructure web, which functions as a scrim, which in turn may beassociated with another meltblown fibrous structure web 24 (mono-fibrouselement fibrous structure web) such that the wet-laid fibrous structureweb 26 is positioned between the two co-formed fibrous structure webs 22may be used in the multi-ply fibrous structure-containing article 20 ofthe present invention.

In one example, as shown in FIG. 15, a multi-ply fibrousstructure-containing article 20 of the present invention comprises twofibrous structure plies: 1) first and second fibrous structure pliesexamples of which are shown in FIGS. 6A and 6B comprising a twodifferent co-formed fibrous structure webs 22 or a variable density (inthe z-direction) co-formed fibrous structure web 30 example of which isshown in FIGS. 16A and 16B (multi-fibrous element fibrous structure web)associated with one meltblown fibrous structure web 24 (mono-fibrouselement fibrous structure web) on one surface of the co-formed fibrousstructure web 22 and a wet-laid fibrous structure web 26 (a mono-fibrouselement fibrous structure web), for example direct formed on thewet-laid fibrous structure web, which functions as a scrim, for examplea textured wet-laid fibrous structure web, such as a 3D patternedwet-laid fibrous structure web on the opposite surface of the co-formedfibrous structure web 22. The wet-laid fibrous structure web 26 may befurther associated with a meltblown fibrous structure web 24(mono-fibrous element fibrous structure web) on the wet-laid fibrousstructure web's surface opposite the co-formed fibrous structure web 22.The fibrous structure plies may be associated with each other in oneoperation, such as by combining the two fibrous plies such that thewet-laid fibrous structure webs 26 are positioned between the twoco-formed fibrous structure webs 22 in the multi-ply fibrousstructure-containing article 20. In one example, the article 20 shown inFIG. 15 is made by combining the pre-formed fibrous structure plies.

In one example, as shown in FIG. 17, a multi-ply fibrousstructure-containing article 20 of the present invention comprises twofibrous structure plies: 1) first and second fibrous structure pliesexamples of which are shown in FIGS. 6A and 6B comprising a co-formedfibrous structure web 22 (multi-fibrous element fibrous structure web)associated with one meltblown fibrous structure web 24 (mono-fibrouselement fibrous structure web) on one surface of the co-formed fibrousstructure web 22 and a wet-laid fibrous structure web 26 (a mono-fibrouselement fibrous structure web), for example direct formed on thewet-laid fibrous structure web, which functions as a scrim, for examplea textured wet-laid fibrous structure web, such as a 3D patternedwet-laid fibrous structure web on the opposite surface of the co-formedfibrous structure web 22. The wet-laid fibrous structure web 26 may befurther associated with a meltblown fibrous structure web 24(mono-fibrous element fibrous structure web) on the wet-laid fibrousstructure web's surface opposite the co-formed fibrous structure web 22.The fibrous structure plies may be associated with each other in oneoperation, such as by combining the two fibrous structure plies suchthat the co-formed fibrous structure webs 22 are positioned between thetwo wet-laid fibrous structure webs 26 in the multi-ply fibrousstructure-containing article 20. In one example, the multi-ply fibrousstructure-containing article 20 shown in FIG. 17 is made by combiningthe pre-formed fibrous structure plies. The multi-ply fibrousstructure-containing article 20 shown in FIG. 17 is similar to themulti-ply fibrous structure-containing article 20 shown in FIG. 7, witha different arrangement of the fibrous structure plies and/or fibrousstructure webs within the multi-ply fibrous structure-containing article20.

In one example, as shown in FIG. 18, a multi-ply fibrousstructure-containing article 20 of the present invention comprises threefibrous structure plies: 1) a first fibrous structure ply) example ofwhich is shown in FIGS. 2A and 2B comprising a co-formed fibrousstructure web 22 (a multi-fibrous element fibrous structure web)associated with two meltblown fibrous structure webs 24 (mono-fibrouselement fibrous structure webs), which function as scrims on oppositesurfaces of the co-formed fibrous structure web 22 forming a co-formedfibrous structure ply 28, 2) second and third fibrous structure pliescomprising wet-laid fibrous structure webs 26 (mono-fibrous elementfibrous structure webs), for example a textured wet-laid fibrousstructure web, for example a textured wet-laid fibrous structure web,such as a 3D patterned wet-laid fibrous structure web associated withthe co-formed fibrous structure ply 28. The wet-laid fibrous structureweb 26 may also be associated with one or more meltblown fibrousstructure webs 24 present on one or both of the wet-laid fibrousstructure web's surfaces. FIG. 19 shows a similar multi-ply fibrousstructure-containing article 20 to that shown in FIG. 18 except that thewet-laid fibrous structure web 26 forms at least one or both of theexterior surfaces of the multi-ply fibrous structure-containing article20. In otherwords, the wet-laid fibrous structure web 26 is notassociated with a meltblown fibrous structure web scrim that forms anexterior surface of the multi-ply fibrous structure-containing article20. The fibrous structure plies may be associated with each other in oneoperation or in multiple operations, such as by combining two of thefibrous structure plies first and then combining the remaining fibrousstructure ply with the already combined fibrous structure plies. In oneexample, the multi-ply fibrous structure-containing article 20 shown inFIG. 18 is made by combining the pre-formed fibrous structure plies.

In one example, as shown in FIG. 20, a multi-ply fibrousstructure-containing article 20 of the present invention comprises twofibrous structure plies: 1) first and second fibrous structure pliesexamples of which are shown in FIGS. 21A and 21B comprising a co-formedfibrous structure web 22 (a multi-fibrous element fibrous structure web)associated with two meltblown fibrous structure webs 24 (mono-fibrouselement fibrous structure webs), which function as scrims on oppositesurfaces of the co-formed fibrous structure web 22 forming a co-formedfibrous structure ply 28, wherein the co-formed fibrous structure ply 28is associated with a wet-laid fibrous structure web 26 (mono-fibrouselement fibrous structure web), for example a textured wet-laid fibrousstructure web, such as a 3D patterned wet-laid fibrous structure web.The wet-laid fibrous structure web 26 may be associated with one or moremeltblown fibrous structure webs 24 present on one or both of thewet-laid fibrous structure web's surfaces. The fibrous structure pliesmay be associated with each other in one operation, such as by combiningthe fibrous structure plies such that the wet-laid fibrous structurewebs 26 are positioned between the co-formed fibrous structure plies 28.In one example, the multi-ply fibrous structure-containing article 20shown in FIG. 20 is made by combining the pre-formed fibrous structureplies).

In one example, as shown in FIGS. 22A and 22B, a multi-ply fibrousstructure-containing article 20 of the present invention comprises twofibrous structure plies: 1) first and second fibrous structure pliesexamples of which are shown in FIGS. 23A and 23B comprising a co-formedfibrous structure web 22 (a multi-fibrous element fibrous structure web)associated with two meltblown fibrous structure webs 24 (mono-fibrouselement fibrous structure webs), which function as scrims on oppositesurfaces of the co-formed fibrous structure web 22 forming a co-formedfibrous structure ply 28, wherein the co-formed fibrous structure ply 28is associated with a wet-laid fibrous structure web 26 (mono-fibrouselement fibrous structure web), for example a textured wet-laid fibrousstructure web, such as a 3D patterned wet-laid fibrous structure web.The wet-laid fibrous structure web 26 may be associated with one or moremeltblown fibrous structure webs 24 present on one or both of thewet-laid fibrous structure web's surfaces. The fibrous structure pliesmay be associated with each other in one operation, such as by combiningthe fibrous structure plies such that the wet-laid fibrous structurewebs 26 are positioned between the co-formed fibrous plies 28. In oneexample, the multi-ply fibrous structure-containing article 20 shown inFIGS. 22A and 22B is made by combining the pre-formed fibrous structureplies.

In one example, as shown in FIGS. 24A and 24B, a multi-ply fibrousstructure-containing article 20 of the present invention comprises twofibrous structure plies: 1) first and second fibrous structure pliesexamples of which are shown in FIGS. 25A and 25B comprising a co-formedfibrous structure web 22 (a multi-fibrous element fibrous structure web)associated with two meltblown fibrous structure webs 24 (mono-fibrouselement fibrous structure webs), which function as scrims on oppositesurfaces of the co-formed fibrous structure web 22 forming a co-formedfibrous structure ply 28, wherein the co-formed fibrous structure ply 28is associated with a wet-laid fibrous structure web 26 (mono-fibrouselement fibrous structure web), for example a textured wet-laid fibrousstructure web, such as a 3D patterned wet-laid fibrous structure web.The wet-laid fibrous structure web 26 may be associated with one or moremeltblown fibrous structure webs 24 present on one or both of thewet-laid fibrous structure web's surfaces. The fibrous structure pliesmay be associated with each other in one operation, such as by combiningthe fibrous structure plies such that the wet-laid fibrous structurewebs 26 are positioned between the co-formed fibrous plies 28. In oneexample, the multi-ply fibrous structure-containing article 20 shown inFIGS. 24A and 24B is made by combining the pre-formed fibrous fibrousstructure plies.

In one example, as shown in FIGS. 26A and 26B, a multi-ply fibrousstructure-containing article 20 of the present invention comprises twofibrous structure plies: 1) first and second fibrous structure pliesexamples of which are shown in FIGS. 27A and 27B comprising a co-formedfibrous structure web 22 (a multi-fibrous element fibrous structure web)associated with two meltblown fibrous structure webs 24 (mono-fibrouselement fibrous structure webs), which function as scrims on oppositesurfaces of the co-formed fibrous structure web 22 forming a co-formedfibrous structure ply 28, wherein the co-formed fibrous structure ply 28is associated with a wet-laid fibrous structure web 26 (mono-fibrouselement fibrous structure web), for example a textured wet-laid fibrousstructure web, such as a 3D patterned wet-laid fibrous structure web.The wet-laid fibrous structure web 26 may be associated with one or moremeltblown fibrous structure webs 24 present on one or both of thewet-laid fibrous structure web's surfaces. The fibrous structure pliesmay be associated with each other in one operation, such as by combiningthe fibrous structure plies such that the wet-laid fibrous structurewebs 26 are positioned between the co-formed fibrous structure plies 28.In one example, the multi-ply fibrous structure-containing article 20shown in FIGS. 26A and 26B is made by combining the pre-formed fibrousstructure plies. Any of the fibrous structure webs and fibrous structureplies within a multi-ply fibrous structure-containing article of thepresent invention may be the same or different from one another (forexample compositionally and/or texturally, etc). For example, two ormore co-formed fibrous structure plies may be the same or different fromone another. For example, two or more wet-laid fibrous structure pliesmay be the same or different (for example compositionally, texturally,etc.) from one another. Further any of the fibrous structure web withina fibrous structure ply may be the same or different (for examplecompositionally, texturally, etc.) from one another.

The articles of the present invention and/or any fibrous webs of thepresent invention may be subjected to any post-processing operationssuch as embossing operations, printing operations, tuft-generatingoperations, thermal bonding operations, ultrasonic bonding operations,perforating operations, surface treatment operations such as applicationof lotions, silicones and/or other materials and mixtures thereof.

The article of the present invention may exhibit one or more of thefollowing properties:

-   -   a. HFS of greater than 17.0 and/or greater than 18.0 and/or        greater than 19.0 and/or greater than 20.0 and/or greater than        22.0 and/or greater than 24.0 g/g as measured according to the        HFS Test Method described herein;    -   b. VFS of greater than 11.0 and/or greater than 11.5 and/or        greater than 12.0 and/or greater than 12.5 and/or greater than        13.0 and/or greater than 13.5 and/or greater than 14.0 g/g as        measured according to the VFS Test Method described herein; and    -   c. Hand Protection Value of greater than 1.00 seconds and/or        greater than 1.25 seconds and/or greater than 1.50 seconds        and/or greater than 1.75 seconds and/or greater than 2.00        seconds and/or greater than 2.25 seconds and/or greater than        2.50 seconds and/or greater than 3.00 seconds and/or greater        than 3.50 seconds and/or greater than 4.00 seconds and/or        greater than 5.00 seconds and/or greater than 7.50 seconds        and/or greater than 10.00 seconds and/or greater than 15.00        seconds and/or greater than 20.00 seconds and/or greater than        22.00 seconds as measured according to the Hand Protection Test        Method described herein.

In addition to or alternatively, the articles, for example articlescomprising a co-formed fibrous structure and optionally other fibrousstructures, of the present invention, when in roll form, may exhibitnovel roll properties. In one example, an article of the presentinvention, for example an article comprising a co-formed fibrousstructure, may exhibit a Roll Firmness at 7.00 N of less than 11.5and/or less 11.0 and/or less than 9.5 and/or less than 9.0 and/or lessthan 8.5 and/or less than 8.0 and/or less than 7.5 mm as measuredaccording to the Roll Firmness Test Method described herein.

In one example, a co-formed fibrous structure and/or a co-formed fibrousweb (co-formed fibrous web ply) in roll form may exhibit a roll firmnessat 7.00 N of less than 11.5 and/or less 11.0 and/or less than 9.5 and/orless than 9.0 and/or less than 8.5 and/or less than 8.0 and/or less than7.5 mm as measured according to the Roll Firmness Test Method describedherein.

Fibrous Webs (Fibrous Web Plies)

Non-limiting examples of fibrous webs (fibrous web plies) according tothe present invention comprise one or more and/or two or more and/orthree or more and/or four or more and/or five or more and/or six or moreand/or seven or more fibrous structures that are associated with oneanother, such as by compression bonding (for example by passing througha nip formed by two rollers), thermal bonding (for example by passingthrough a nip formed by two rollers where at least one of the rollers isheated to a temperature of at least about 120° C. (250° F.)),microselfing, needle punching, and gear rolling, to form a unitarystructure.

Wet-Laid Fibrous Structure (an Example of a Mono-Fibrous Element FibrousStructure)

The wet-laid fibrous structure comprises a plurality of fibrouselements, for example a plurality of fibers. In one example, thewet-laid fibrous structure comprises a plurality of naturally-occurringfibers, for example pulp fibers, such as wood pulp fibers (hardwoodand/or softwood pulp fibers). In another example, the wet-laid fibrousstructure comprises a plurality of non-naturally occurring fibers(synthetic fibers), for example staple fibers, such as rayon, lyocell,polyester fibers, polycaprolactone fibers, polylactic acid fibers,polyhydroxyalkanoate fibers, and mixtures thereof.

The mono-fibrous element fibrous structure may comprise one or morefilaments, such as polyolefin filaments, for example polypropyleneand/or polyethylene filaments, starch filaments, starch derivativefilaments, cellulose filaments, polyvinyl alcohol filaments.

The wet-laid fibrous structure of the present invention may besingle-ply or multi-ply web material. In other words, the wet-laidfibrous structures of the present invention may comprise one or morewet-laid fibrous structures, the same or different from each other solong as one of them comprises a plurality of pulp fibers.

In one example, the wet-laid fibrous structure comprises a wet laidfibrous structure ply, such as a through-air-dried fibrous structureply, for example an uncreped, through-air-dried fibrous structure plyand/or a creped, through-air-dried fibrous structure ply.

In another example, the wet-laid fibrous structure and/or wet laidfibrous structure ply may exhibit substantially uniform density.

In another example, the wet-laid fibrous structure and/or wet laidfibrous structure ply may comprise a surface pattern.

In one example, the wet laid fibrous structure ply comprises aconventional wet-pressed fibrous structure ply. The wet laid fibrousstructure ply may comprise a fabric-creped fibrous structure ply. Thewet laid fibrous structure ply may comprise a belt-creped fibrousstructure ply.

In still another example, the wet-laid fibrous structure may comprise anair laid fibrous structure ply.

The wet-laid fibrous structures of the present invention may comprise asurface softening agent or be void of a surface softening agent, such assilicones, quaternary ammonium compounds, lotions, and mixtures thereof.In one example, the sanitary tissue product is a non-lotioned wet-laidfibrous structure.

The wet-laid fibrous structures of the present invention may comprisetrichome fibers or may be void of trichome fibers.

Patterned Molding Members

The wet-laid fibrous structures of the present invention may be formedon patterned molding members that result in the wet-laid fibrousstructures of the present invention. In one example, the pattern moldingmember comprises a non-random repeating pattern. In another example, thepattern molding member comprises a resinous pattern.

In one example, the wet-laid fibrous structure comprises a texturedsurface. In another example, the wet-laid fibrous structure comprises asurface comprising a three-dimensional (3D) pattern, for example a 3Dpattern imparted to the wet-laid fibrous structure by a patternedmolding member. Non-limiting examples of suitable patterned moldingmembers include patterned felts, patterned forming wires, patternedrolls, patterned fabrics, and patterned belts utilized in conventionalwet-pressed papermaking processes, air-laid papermaking processes,and/or wet-laid papermaking processes that produce 3D patterned sanitarytissue products and/or 3D patterned fibrous structure plies employed insanitary tissue products. Other non-limiting examples of such patternedmolding members include through-air-drying fabrics andthrough-air-drying belts utilized in through-air-drying papermakingprocesses that produce through-air-dried fibrous structures, for example3D patterned through-air dried fibrous structures, and/orthrough-air-dried sanitary tissue products comprising the wet-laidfibrous structure.

A “reinforcing element” may be a desirable (but not necessary) elementin some examples of the molding member, serving primarily to provide orfacilitate integrity, stability, and durability of the molding membercomprising, for example, a resinous material. The reinforcing elementcan be fluid-permeable or partially fluid-permeable, may have a varietyof embodiments and weave patterns, and may comprise a variety ofmaterials, such as, for example, a plurality of interwoven yarns(including Jacquard-type and the like woven patterns), a felt, aplastic, other suitable synthetic material, or any combination thereof.

Non-limiting examples of patterned molding members suitable for use inthe present invention comprises a through-air-drying belts. Thethrough-air-drying belts may comprise a plurality of continuousknuckles, discrete knuckles, semi-continuous knuckles and/or continuouspillows, discrete pillows, and semi-continuous pillows formed by resinarranged in a non-random, repeating pattern supported on a supportfabric comprising filaments, such as a forming fabric. The resin ispatterned such that deflection conduits that contain little to knowresin present in the pattern and result in the fibrous structure beingformed on the patterned molding member having one or more pillow regions(low density regions) compared to the knuckle regions that are impartedto the fibrous structure by the resin areas.

Non-limiting Examples of Making Wet-laid Fibrous Structures

In one non-limiting example, the wet-laid fibrous structure is made on amolding member of the present invention. The method may be a wet-laidfibrous structure making process that uses a cylindrical dryer such as aYankee (a Yankee-process) (creped) or it may be a Yankeeless process(uncreped) as is used to make substantially uniform density and/oruncreped wet-laid fibrous structures (fibrous structures).

In one example, a process for making a wet-laid fibrous structureaccording to the present invention comprises supplying an aqueousdispersion of fibers (a fibrous or fiber furnish or fiber slurry) to aheadbox which can be of any convenient design. From the headbox theaqueous dispersion of fibers is delivered to a first foraminous member(forming wire) which is typically a Fourdrinier wire, to produce anembryonic fibrous structure.

The embryonic fibrous structure is brought into contact with a patternedmolding member, such as a 3D patterned through-air-drying belt. While incontact with the patterned molding member, the embryonic fibrousstructure will be deflected, rearranged, and/or further dewatered. Thiscan be accomplished by applying differential speeds and/or pressures.

After the embryonic fibrous structure has been associated with thepatterned molding member, fibers within the embryonic fibrous structureare deflected into pillows (“deflection conduits”) present in thepatterned molding member. In one example of this process step, there isessentially no water removal from the embryonic fibrous structurethrough the deflection conduits after the embryonic fibrous structurehas been associated with the patterned molding member but prior to thedeflecting of the fibers into the deflection conduits. Further waterremoval from the embryonic fibrous structure can occur during and/orafter the time the fibers are being deflected into the deflectionconduits. Water removal from the embryonic fibrous structure maycontinue until the consistency of the embryonic fibrous structureassociated with patterned molding member is increased to from about 25%to about 35%. Once this consistency of the embryonic fibrous structureis achieved, then the embryonic fibrous structure can be referred to asan intermediate fibrous structure. As noted, water removal occurs bothduring and after deflection; this water removal may result in a decreasein fiber mobility in the embryonic web material. This decrease in fibermobility may tend to fix and/or freeze the fibers in place after theyhave been deflected and rearranged. Of course, the drying of the webmaterial in a later step in the process of this invention serves to morefirmly fix and/or freeze the fibers in position.

Any convenient means conventionally known in the papermaking art can beused to dry the intermediate fibrous structure. Examples of suchsuitable drying process include subjecting the intermediate fibrousstructure to conventional and/or flow-through dryers and/or Yankeedryers.

In one example of a drying process, the intermediate fibrous structuremay first pass through an optional predryer. This predryer can be aconventional flow-through dryer (hot air dryer) well known to thoseskilled in the art. Optionally, the predryer can be a so-calledcapillary dewatering apparatus. In such an apparatus, the intermediatefibrous structure passes over a sector of a cylinder havingpreferential-capillary-size pores through its cylindrical-shaped porouscover. Optionally, the predryer can be a combination capillarydewatering apparatus and flow-through dryer. The quantity of waterremoved in the predryer may be controlled so that a predried fibrousstructure exiting the predryer has a consistency of from about 30% toabout 98%. The predried fibrous structure may be applied to a surface ofa Yankee dryer via a nip with pressure, the pattern formed by the topsurface of patterned molding member is impressed into the predried webmaterial to form a 3D patterned fibrous structure, for example a 3Dpatterned wet-laid fibrous structure of the present invention. The 3Dpatterned wet-laid fibrous structure is then adhered to the surface ofthe Yankee dryer where it can be dried to a consistency of at leastabout 95%.

The 3D patterned wet-laid fibrous structure can then be foreshortened bycreping the 3D patterned wet-laid fibrous structure with a creping bladeto remove the 3D patterned wet-laid fibrous structure from the surfaceof the Yankee dryer resulting in the production of a 3D patterned crepedwet-laid fibrous structure in accordance with the present invention. Asused herein, foreshortening refers to the reduction in length of a dry(having a consistency of at least about 90% and/or at least about 95%)web material which occurs when energy is applied to the dry web materialin such a way that the length of the dry web material is reduced and thefibers in the dry web material are rearranged with an accompanyingdisruption of fiber-fiber bonds. Foreshortening can be accomplished inany of several well-known ways. One common method of foreshortening iscreping. Another method of foreshortening that is used to make thewet-laid fibrous structures of the present invention is wetmicrocontraction. Further, the wet-laid fibrous structure may besubjected to post processing steps such as calendaring, tuft generatingoperations, and/or embossing and/or converting.

Co-Formed Fibrous Structures

The co-formed fibrous structures of the present invention comprise aplurality of filaments and a plurality of solid additives. The filamentsand the solid additives may be commingled together. In one example, thefibrous structure is a coform fibrous structure comprising filaments andsolid additives. The filaments may be present in the fibrous structuresof the present invention at a level of less than 90% and/or less than80% and/or less than 65% and/or less than 50% and/or greater than 5%and/or greater than 10% and/or greater than 20% and/or from about 10% toabout 50% and/or from about 25% to about 45% by weight of the fibrousstructure on a dry basis.

The solid additives may be present in the fibrous structures of thepresent invention at a level of greater than 10% and/or greater than 25%and/or greater than 50% and/or less than 100% and/or less than 95%and/or less than 90% and/or less than 85% and/or from about 30% to about95% and/or from about 50% to about 85% by weight of the fibrousstructure on a dry basis.

The filaments and solid additives may be present in the fibrousstructures of the present invention at a weight ratio of filaments tosolid additive of greater than 10:90 and/or greater than 20:80 and/orless than 90:10 and/or less than 80:20 and/or from about 25:75 to about50:50 and/or from about 30:70 to about 45:55. In one example, thefilaments and solid additives are present in the fibrous structures ofthe present invention at a weight ratio of filaments to solid additivesof greater than 0 but less than 1.

In one example, the fibrous structures of the present invention exhibita basis weight of from about 10 gsm to about 1000 gsm and/or from about10 gsm to about 500 gsm and/or from about 15 gsm to about 400 gsm and/orfrom about 15 gsm to about 300 gsm as measured according to the BasisWeight Test Method described herein. In another example, the fibrousstructures of the present invention exhibit a basis weight of from about10 gsm to about 200 gsm and/or from about 20 gsm to about 150 gsm and/orfrom about 25 gsm to about 125 gsm and/or from about 30 gsm to about 100gsm and/or from about 30 gsm to about 80 gsm as measured according tothe Basis Weight Test Method described herein. In still another example,the fibrous structures of the present invention exhibit a basis weightof from about 80 gsm to about 1000 gsm and/or from about 125 gsm toabout 800 gsm and/or from about 150 gsm to about 500 gsm and/or fromabout 150 gsm to about 300 gsm as measured according to the Basis WeightTest Method described herein.

In one example, the fibrous structure of the present invention comprisesa core component. A “core component” as used herein means a fibrousstructure comprising a plurality of filaments and optionally a pluralityof solid additives. In one example, the core component is a coformfibrous structure comprising a plurality of filaments and a plurality ofsolid additives, for example pulp fibers. In one example, the corecomponent is the component that exhibits the greatest basis weight withthe fibrous structure of the present invention. In one example, thetotal core components present in the fibrous structures of the presentinvention exhibit a basis weight that is greater than 50% and/or greaterthan 55% and/or greater than 60% and/or greater than 65% and/or greaterthan 70% and/or less than 100% and/or less than 95% and/or less than 90%of the total basis weight of the fibrous structure of the presentinvention as measured according to the Basis Weight Test Methoddescribed herein. In another example, the core component exhibits abasis weight of greater than 12 gsm and/or greater than 14 gsm and/orgreater than 16 gsm and/or greater than 18 gsm and/or greater than 20gsm and/or greater than 25 gsm as measured according to the Basis WeightTest Method described herein.

“Consolidated region” as used herein means a region within a fibrousstructure where the filaments and optionally the solid additives havebeen compressed, compacted, and/or packed together with pressure andoptionally heat (greater than 150° F.) to strengthen the region comparedto the same region in its unconsolidated state or a separate regionwhich did not see the compression or compacting pressure. In oneexample, a region is consolidated by forming unconsolidated regionswithin a fibrous structure on a patterned molding member and passing theunconsolidated regions within the fibrous structure while on thepatterned molding member through a pressure nip, such as a heated metalanvil roll (about 275° F.) and a rubber anvil roll with pressure tocompress the unconsolidated regions into one or more consolidatedregions. In one example, the filaments present in the consolidatedregion, for example on the side of the fibrous structure that iscontacted by the heated roll comprises fused filaments that create askin on the surface of the fibrous structure, which may be visible viaSEM images.

The fibrous structure of the present invention may, in addition a corecomponent, further comprise a scrim component. “Scrim component” as usedherein means a fibrous structure comprising a plurality of filaments. Inone example, the total scrim components present in the fibrousstructures of the present invention exhibit a basis weight that is lessthan 25% and/or less than 20% and/or less than 15% and/or less than 10%and/or less than 7% and/or less than 5% and/or greater than 0% and/orgreater than 1% of the total basis weight of the fibrous structure ofthe present invention as measured according to the Basis Weight TestMethod described herein. In another example, the scrim componentexhibits a basis weight of 10 gsm or less and/or less than 10 gsm and/orless than 8 gsm and/or less than 6 gsm and/or greater than 5 gsm and/orless than 4 gsm and/or greater than 0 gsm and/or greater than 1 gsm asmeasured according to the Basis Weight Test Method described herein.

In one example, at least one of the core components of the fibrousstructure comprises a plurality of solid additives, for example pulpfibers, such as comprise wood pulp fibers and/or nonwood pulp fibers.

In one example, at least one of the core components of the fibrousstructure comprises a plurality of core filaments. In another example,at least one of the core components comprises a plurality of solidadditives and a plurality of the core filaments. In one example, thesolid additives and the core filaments are present in a layeredorientation within the core component. In one example, the corefilaments are present as a layer between two solid additive layers. Inanother example, the solid additives and the core filaments are presentin a coform layer. At least one of the core filaments comprises apolymer, for example a thermoplastic polymer, such as a polyolefin. Thepolyolefin may be selected from the group consisting of: polypropylene,polyethylene, and mixtures thereof. In another example, thethermoplastic polymer of the core filament may comprise a polyester.

In one example, at least one of the scrim components is adjacent to atleast one of the core components within the fibrous structure. Inanother example, at least one of the core components is positionedbetween two scrim components within the fibrous structure.

In one example, at least one of the scrim components of the fibrousstructure of the present invention comprises a plurality of scrimfilaments, for example scrim filaments, wherein the scrim filamentscomprise a polymer, for example a thermoplastic and/or hydroxyl polymeras described above with reference to the core components.

In one example, at least one of the scrim filaments exhibits an averagefiber diameter of less than 50 and/or less than 25 and/or less than 10and/or at least 1 and/or greater than 1 and/or greater than 3 μm asmeasured according to the Average Diameter Test Method described herein.

The average fiber diameter of the core filaments is less than 250 and/orless than 200 and/or less than 150 and/or less than 100 and/or less than50 and/or less than 30 and/or less than 25 and/or less than 10 and/orgreater than 1 and/or greater than 13 μm as measured according to theAverage Diameter Test Method described herein.

In one example, the fibrous structures of the present invention maycomprise any suitable amount of filaments and any suitable amount ofsolid additives. For example, the fibrous structures may comprise fromabout 10% to about 70% and/or from about 20% to about 60% and/or fromabout 30% to about 50% by dry weight of the fibrous structure offilaments and from about 90% to about 30% and/or from about 80% to about40% and/or from about 70% to about 50% by dry weight of the fibrousstructure of solid additives, such as wood pulp fibers.

In one example, the filaments and solid additives of the presentinvention may be present in fibrous structures according to the presentinvention at weight ratios of filaments to solid additives of from atleast about 1:1 and/or at least about 1:1.5 and/or at least about 1:2and/or at least about 1:2.5 and/or at least about 1:3 and/or at leastabout 1:4 and/or at least about 1:5 and/or at least about 1:7 and/or atleast about 1:10.

In one example, the solid additives, for example wood pulp fibers, maybe selected from the group consisting of softwood kraft pulp fibers,hardwood pulp fibers, and mixtures thereof. Non-limiting examples ofhardwood pulp fibers include fibers derived from a fiber source selectedfrom the group consisting of: Acacia, Eucalyptus, Maple, Oak, Aspen,Birch, Cottonwood, Alder, Ash, Cherry, Elm, Hickory, Poplar, Gum,Walnut, Locust, Sycamore, Beech, Catalpa, Sassafras, Gmelina, Albizia,Anthocephalus, and Magnolia. Non-limiting examples of softwood pulpfibers include fibers derived from a fiber source selected from thegroup consisting of: Pine, Spruce, Fir, Tamarack, Hemlock, Cypress, andCedar. In one example, the hardwood pulp fibers comprise tropicalhardwood pulp fibers. Non-limiting examples of suitable tropicalhardwood pulp fibers include Eucalyptus pulp fibers, Acacia pulp fibers,and mixtures thereof.

In one example, the wood pulp fibers comprise softwood pulp fibersderived from the kraft process and originating from southern climates,such as Southern Softwood Kraft (SSK) pulp fibers. In another example,the wood pulp fibers comprise softwood pulp fibers derived from thekraft process and originating from northern climates, such as NorthernSoftwood Kraft (NSK) pulp fibers.

The wood pulp fibers present in the fibrous structure may be present ata weight ratio of softwood pulp fibers to hardwood pulp fibers of from100:0 and/or from 90:10 and/or from 86:14 and/or from 80:20 and/or from75:25 and/or from 70:30 and/or from 60:40 and/or about 50:50 and/or to0:100 and/or to 10:90 and/or to 14:86 and/or to 20:80 and/or to 25:75and/or to 30:70 and/or to 40:60. In one example, the weight ratio ofsoftwood pulp fibers to hardwood pulp fibers is from 86:14 to 70:30.

In one example, the fibrous structures of the present invention compriseone or more trichomes. Non-limiting examples of suitable sources forobtaining trichomes, especially trichome fibers, are plants in theLabiatae (Lamiaceae) family commonly referred to as the mint family.Examples of suitable species in the Labiatae family include Stachysbyzantina, also known as Stachys lanata commonly referred to as lamb'sear, woolly betony, or woundwort. The term Stachys byzantina as usedherein also includes cultivars Stachys byzantina ‘Primrose Heron’,Stachys byzantina ‘Helene von Stein’ (sometimes referred to as Stachysbyzantina ‘Big Ears’), Stachys byzantina ‘Cotton Boll’, Stachysbyzantina ‘Variegated’ (sometimes referred to as Stachys byzantina‘Striped Phantom’), and Stachys byzantina ‘Silver Carpet’.

Non-limiting examples of suitable polypropylenes for making thefilaments of the present invention are commercially available fromLyondell-Basell and Exxon-Mobil.

Any hydrophobic or non-hydrophilic materials within the fibrousstructure, such as polypropylene filaments, may be surface treatedand/or melt treated with a hydrophilic modifier. Non-limiting examplesof surface treating hydrophilic modifiers include surfactants, such asTriton X-100. Non-limiting examples of melt treating hydrophilicmodifiers that are added to the melt, such as the polypropylene melt,prior to spinning filaments, include hydrophilic modifying meltadditives such as VW351 and/or S-1416 commercially available fromPolyvel, Inc. and Irgasurf commercially available from Ciba. Thehydrophilic modifier may be associated with the hydrophobic ornon-hydrophilic material at any suitable level known in the art. In oneexample, the hydrophilic modifier is associated with the hydrophobic ornon-hydrophilic material at a level of less than about 20% and/or lessthan about 15% and/or less than about 10% and/or less than about 5%and/or less than about 3% to about 0% by dry weight of the hydrophobicor non-hydrophilic material.

The fibrous structures of the present invention may include optionaladditives, each, when present, at individual levels of from about 0%and/or from about 0.01% and/or from about 0.1% and/or from about 1%and/or from about 2% to about 95% and/or to about 80% and/or to about50% and/or to about 30% and/or to about 20% by dry weight of the fibrousstructure. Non-limiting examples of optional additives include permanentwet strength agents, temporary wet strength agents, dry strength agentssuch as carboxymethylcellulose and/or starch, softening agents, lintreducing agents, opacity increasing agents, wetting agents, odorabsorbing agents, perfumes, temperature indicating agents, color agents,dyes, osmotic materials, microbial growth detection agents,antibacterial agents, liquid compositions, surfactants, and mixturesthereof.

The fibrous structure of the present invention may itself be a sanitarytissue product. It may be convolutedly wound about a core to form aroll. It may be combined with one or more other fibrous structures as aply to form a multi-ply sanitary tissue product. In one example, aco-formed fibrous structure of the present invention may be convolutedlywound about a core to form a roll of co-formed sanitary tissue product.The rolls of sanitary tissue products may also be coreless.

Method for Making a Co-Formed Fibrous Structure

A non-limiting example of a method for making a fibrous structureaccording to the present invention comprises the steps of: 1) collectinga mixture of filaments and solid additives, such as fibers, for examplepulp fibers, onto a collection device, for example a through-air-dryingfabric or other fabric or a patterned molding member of the presentinvention. This step of collecting the filaments and solid additives onthe collection device may comprise subjecting the co-formed fibrousstructure while on the collection device to a consolidation step wherebythe co-formed fibrous structure, while present on the collection device,is pressed between a nip, for example a nip formed by a flat or evensurface rubber roll and a flat or even surface or patterned, heated(with oil) or unheated metal roll.

In another example, the co-forming method may comprise the steps of a)collecting a plurality of filaments onto a collection device, forexample a belt or fabric, such as a patterned molding member, to form ascrim component (a meltblown fibrous structure. The collection of theplurality of filaments onto the collection device to form the scrimcomponent may be vacuum assisted by a vacuum box.

Once the scrim component (meltblown fibrous structure) is formed on thecollection device, the next step is to mix, such as commingle, aplurality of solid additives, such as fibers, for example pulp fibers,such as wood pulp fibers, with a plurality of filaments, such as in acoform box, and collecting the mixture on the scrim component carried onthe collection device to form a core component. Optionally, anadditional scrim component (meltblown fibrous structure) comprisingfilaments may be added to the core component to sandwich the corecomponent between two scrim components.

The meltblown die used to make the meltblown fibrous structures and/orfilaments herein may be a multi-row capillary die and/or a knife-edgedie. In one example, the meltblown die is a multi-row capillary die.

Method for Making Multi-ply Fibrous Structure-containing Article

The multi-ply fibrous structure-containing articles of the presentinvention are made by combining two or more and/or three or more and/orfour or more fibrous structure plies as described herein, wherein atleast one of the fibrous structure plies is embossed, for examplecomprises embossments such that the fibrous structure ply exhibits aCore Height Value (MikroCAD Value)s of greater than 0.60 mm and/orgreater than 0.75 mm and/or greater than 0.90 mm and/or greater than1.00 mm and/or greater than 1.10 mm and/or greater than 1.20 mm and/orgreater than 1.30 mm and/or greater than 1.40 mm and/or greater than1.50 mm and/or greater than 1.60 mm and/or greater than 1.70 mm asmeasured according to the Surface Texture Analysis Test Method describedherein and/or a Core Height Difference Value (MikroCAD Difference Value)of greater than 0.50 mm and/or greater than 0.55 mm and/or greater than0.60 mm and/or greater than 0.64 mm and/or greater than 0.75 mm and/orgreater than 0.84 mm and/or greater than 0.95 mm and/or greater than1.00 mm and/or greater than 1.05 mm and/or greater than 1.10 mm and/orgreater than 1.15 mm and/or greater than 1.20 mm and/or greater than1.25 mm and/or at least 1.30 mm as measured according to the SurfaceTexture Analysis Test Method described herein.

An exemplary process for embossing a fibrous structure ply and/ormulti-ply fibrous structure-containing article in accordance with thepresent invention incorporates the use of a deep-nested embossmenttechnology. By way of a non-limiting example, a fibrous structure ply isembossed in a gap between two embossing rolls. The embossing rolls maybe made from any material known for making such rolls, including,without limitation, steel, rubber, elastomeric materials, andcombinations thereof. As known to those of skill in the art, eachembossing roll may be provided with a combination of emboss protrusionsand gaps. Each emboss protrusion comprises a base, a face, and one ormore sidewalls. Each emboss protrusion also has a height. The height ofthe emboss protrusions may range from about 1.8 mm. (0.070 in.) to about3.8 mm. (0.150 in.), in one embodiment from about 2.0 mm. (0.080 in.) toabout 3.3 mm. (0.130 in.). Each embossing roll may be heated to helpfacilitate thermal bonding of the fibrous structure plies togetherresulting in one or more water-resistant bonds, for example one or morethermal bonds 74.

FIGS. 28A and 28B show an example of an embossing apparatus 50 inaccordance with the present invention. The embossing apparatus 50includes a pair of embossing rolls 52 and 54 (a first embossing roll 52and a second embossing roll 54). (It should be noted that theembodiments shown in the figures are just exemplary embodiments andother embodiments are certainly contemplated. For example, the embossingrolls 52 and 54 of the embodiment shown in FIGS. 28A and 28B could bereplaced with any other embossing members such as, for example, plates,cylinders or other equipment suitable for embossing fibrous structureplies and/or fibrous structure webs. Further, additional equipment andsteps that are not specifically described herein may be added to theembossing apparatus 50 and/or process of the present invention.) Theembossing rolls 52 and 54 are disposed adjacent each other to provide anip 56. The embossing rolls 52 and 54 are generally configured so as tobe rotatable on an axis, the axes 58 and 60, respectively, of theembossing rolls 52 and 54 are typically generally parallel to oneanother. The embossing apparatus 50 may be contained within a typicalembossing device housing. As shown in FIGS. 28A and 28B, the embossingrolls 52 and 54 provide a nip 56 through which a fibrous structure ply,for example a co-formed fibrous structure ply 28, and/or a fibrousstructure web, for example a wet-laid fibrous structure web, can pass.

FIG. 28B is an enlarged view of the portion of the embossing apparatus50 labeled 28B in FIG. 28A. FIG. 28B shows a more detailed view of thefibrous structure ply, for example a co-formed fibrous structure ply 28,and/or a fibrous structure web, for example a wet-laid fibrous structureweb passing through the nip 56 between the embossing rolls 52 and 54. Ascan be seen in FIG. 28B, the first embossing roll 52 includes aplurality of first embossing protrusions 62 extending from the outersurface 64 of the first embossing roll 52. The second embossing roll 54includes a plurality of second embossing protrusions 66 extendingoutwardly from the outer surface 68 of the second embossing roll 54. Thefirst embossing protrusions 62 and the second embossing protrusions 66are generally arranged in a non-random pattern. (It should be noted thatwhen the embossing protrusions 62 and/or 66 are described as extendingfrom an outer surface of an embossing roll, the embossing protrusionsmay be integral with the surface of the embossing roll and/or may beseparate protrusions that are joined to the surface of the embossingroll.) As the fibrous structure ply, for example a co-formed fibrousstructure ply 28, and/or a fibrous structure web, for example a wet-laidfibrous structure web is passed through the nip 56, it is nested andmacroscopically deformed by the intermeshing of the first embossingprotrusions 62 and the second embossing protrusions 66. The embossingshown is deep-nested embossing, as described herein, because the firstembossing protrusions 62 and the second embossing protrusions 66intermesh with each other, for example like the teeth of gears. Thus,the resulting fibrous structure ply, for example a co-formed fibrousstructure ply 28, and/or a fibrous structure web, for example a wet-laidfibrous structure web is deeply embossed and nested, for example tocreate the Core Height Values (MikroCAD Values) and Core HeightDifference Values (MikroCAD Difference Values) as described herein, andincludes plurality of undulations that can add bulk and caliper to thefibrous structure ply, for example a co-formed fibrous structure ply 28,and/or a fibrous structure web, for example a wet-laid fibrous structureweb.

The embossing rolls 52 and 54, including the outer surfaces of the rolls64 and 68 as well as the embossing protrusions 62 and 66, may be madeout of any material suitable for the desired embossing process. Suchmaterials include, without limitation, steel and other metals, ebonite,and hard rubber or a combination thereof. In addition any of thecomponents of the embossing rolls 52 and 54 (embossing protrusions 62and 66 and outer surfaces 64 and 68) can be heated to facilitatesoftening of the fibrous structure ply and/or fibrous structure weband/or thermal bonding between fibrous structure plies resulting inbonds 74, in this case water-resistant bonds, for example thermal bondsand/or water-resistant adhesive bonds.

In one example, as shown in FIGS. 29A-29C, two or more plies of the sameor different fibrous structures. In one example, a first fibrousstructure ply, for example a co-formed fibrous structure ply 28, awet-laid fibrous structure ply 26, or a direct formed fibrous structureply 78 is subjected to a high definition emboss (HDE) process to createembossments as shown in more detail in FIG. 29B that exhibit anembossment height of greater than 0.60 mm as measured according to theSurface Texture Analysis Test Method, which is combined with at leastone other fibrous structure ply, for example a wet-laid fibrousstructure ply 26, a co-formed fibrous structure ply 28, or a directformed fibrous structure ply 78. Any of the fibrous structure plies maybe the same or different from any other of the fibrous structure plies.For example, two co-formed fibrous structure plies may be the same ordifferent from each other. For example, two wet-laid fibrous structureplies may be the same or different from each other. For example, twodirect formed fibrous structures plies may be the same or different fromeach other. The resulting multi-ply fibrous structure-containing article20 of the present invention is shown in FIG. 29D where a first embossedfibrous structure ply comprising a co-formed fibrous structure web and awet-laid fibrous structure web that exhibits a Core Height Value(MikroCAD Value) of greater than 0.60 mm as measured according to theSurface Texture Analysis Test Method is bonded via a water-resistantbond 74, for example a thermal bond in this case, to a second fibrousstructure ply comprising a co-formed fibrous structure web and awet-laid fibrous structure web such that void volumes between the twoplies exists.

In another example as shown in FIGS. 30A-30C, the process of the presentinvention may comprise the steps of combining/marrying a fibrousstructure ply, for example a co-formed fibrous structure ply 28 and/or awet-laid fibrous structure ply/web 26 and/or a direct formed fibrousstructure ply, with at least one other fibrous structure ply, forexample a co-formed fibrous structure ply 28 and/or a wet-laid fibrousstructure ply/web 26 and/or a direct formed fibrous structure ply, bypassing the fibrous structure plies through a bonding nip, for example athermal bonding nip formed by a thermal bond roll 70 and a highdefinition emboss/thermal bond roll 54 as shown in FIG. 30B to form awater-resistant bonded multi-ply fibrous structure-containing articleand then subsequently passing the water-resistant bonded multi-plyfibrous structure-containing article through a high definition embossnip formed by the high definition emboss/thermal bond roll 54 and a highdefinition emboss roll 52 as shown in FIG. 30C to form an embossedmulti-ply fibrous structure-containing article 20 as shown in FIG. 30D.

In another example as shown in FIGS. 31A-31C, the process of the presentinvention may comprise the steps of embossing a first fibrous structureply, for example a co-formed fibrous structure ply 28 and/or a wet-laidfibrous structure ply/web 26 and/or a direct formed fibrous structureply, with at least one other fibrous structure ply, for example aco-formed fibrous structure ply 28 and/or a wet-laid fibrous structureply/web 26 and/or a direct formed fibrous structure ply, by passing thefirst fibrous structure ply through a first high definition emboss nipformed by the high definition emboss roll 52 and a high definitionemboss/thermal bond roll 54 as shown in FIG. 31B; embossing a secondfibrous structure ply, for example a co-formed fibrous structure ply 28and/or a wet-laid fibrous structure ply/web 26 and/or a direct formedfibrous structure ply, by passing the second fibrous structure plythrough a second high definition emboss nip formed by the highdefinition emboss roll 52 and a high definition emboss/thermal bond roll54 as shown in FIG. 31B and then combining/marrying the embossed firstfibrous structure ply and the embossed second fibrous structure ply bypassing them through a bonding nip formed by two high definitionemboss/thermal bond rolls 54 as shown in FIG. 31C to form an embossedmulti-ply fibrous structure-containing article 20 as shown in FIG. 31D.

In another example as shown in FIG. 32, the process of the presentinvention may comprise the step of embossing a fibrous structure ply,for example a co-formed fibrous structure ply 28 and/or a wet-laidfibrous structure ply/web 26 and/or a direct formed fibrous structureply, with at least one other fibrous structure ply, for example aco-formed fibrous structure ply 28 and/or a wet-laid fibrous structureply/web 26 and/or a direct formed fibrous structure ply, by passing thefibrous structure ply through a high definition emboss nip formed by thehigh definition emboss roll 52 and a high definition emboss/thermal bondroll 54; thermally bonding a co-formed fibrous structure ply 28 with awet-laid fibrous structure web 26 by passing them through a thermal bondnip formed by a thermal bond roll 70 and a rubber roll 76, and themcombining/marrying the embossed fibrous structure ply with the thermallybonded fibrous structure ply by passing them through a bonding nipformed by the thermal bond roll 70 and a high definition emboss/thermalbond roll 54 to form an embossed multi-ply fibrous structure-containingarticle.

In another example as shown in FIG. 33, the process of the presentinvention may comprise the step of embossing a fibrous structure ply,for example a direct formed fibrous structure ply (co-formed fibrousstructure ply 28 directly deposited upon a wet-laid fibrous structureweb 26), by passing the fibrous structure ply through a high definitionemboss nip formed by the high definition emboss roll 52 and a highdefinition emboss/thermal bond roll 54, and them combining/marrying theembossed fibrous structure ply with at least one other fibrous structureply, for example a co-formed fibrous structure ply 28 and/or a wet-laidfibrous structure ply/web 26 and/or a direct formed fibrous structureply, by passing them through a bonding nip formed by the thermal bondroll 70 and a high definition emboss/thermal bond roll 54 to form anembossed multi-ply fibrous structure-containing article.

High definition thermal bonding (HDTB) is the combination of HighDefinition Embossing (HDE) combined with Thermal Bonding. HDE generatesadditional product thickness by straining the fibrous structure plybeyond its elastic yield point. The HDE emboss roll surfaces havespecially designed protuberances. When loaded together, theprotuberances on each roll mesh together. Passing a fibrous structureply through this meshed surface imparts a strain on the fibrousstructure ply thereby altering its properties.

The exact geometry of the HDE emboss elements (protuberances), and theextent to which the emboss rolls are loaded together (engaged with oneanother at a depth of engagement), change the amount of strain which isimparted to the fibrous structure ply, and therefore the amount ofmodification to the material properties. Thermal bonding multiple pliesof product together also impact the properties of the resultingmulti-ply fibrous structure-containing articles.

The amount of strain imparted to fibrous structure plies that passthrough the loaded emboss roll bodies with raised design protuberancescan be roughly calculated. The protuberances have a tooth height(protuberance height) and tooth width (protuberance width). There existsa gap between adjacent protuberances on the opposite emboss roll. Theemboss roll bodies have an interference when loaded. The fibrousstructure plies get significantly strained when the emboss rolls areloaded together.

The amount of localized strain imparted to a fibrous structure ply is afunction of the exact position of the fibrous structure ply relative tothe protuberances on the emboss rolls. However, the average strain canbe calcualted using the geometry while asssuming both slip and non-slipbetween the fibrous structure ply and the surface of the protuberances.These assumptions bound the true amount of strain imparted to thefibrous structure ply.

The amount of strain imparted to a fibrous structure ply is a functionof the amount of interference, the amount of spacing between adjacentelements (protuberances), and the size of the elements (protruberances).

HDE most significantly alters the material properties of the fibrousstructure plies when the geometry associated with the interferencebetween emboss rolls, the spacing between adjacent elements(protuberances) and the size the elements (protuberances) of the meshedprotuberances generate localized strains in the fibrous structure plythat cause permanent deformation up to and including localized failure.Localized failure occurs when the fibrous structure ply is strainedlocally at a value higher than the failure point of the modulus of thefibrous structure ply. Experimentation has shown that localized failuresroughly occur when the calculated strain associated with the HDE processusing interference between emboss rolls, the spacing between adjacentelements (protuberances) and the size the elements (protuberances) ofthe meshed protuberances exceeds the failure strain on the modulus curvewhile assuming slip between the fibrous structure ply and theprotuberances within the HDE nip.

The amount of calculated strain assuming slippage between the sheet andthe emboss roll protuberance while running the HDTB process has been runas high as about 44% but more normally run at about 33%.

The design of the emboss roll elements/protuberances can take manyshapes to accomplish the desired imparted strain intent. Circular ordiscrete dot protuberances when clustered together in a repeatingpattern, generate a repeatable strain profile in the fibrous structureply when the emboss rolls are run to a proper interference.

Line elements (protruberances) can also be used in the HDTB process.Line elements combined with circular or non-line elements can also beused. A pattern of elements may use both line elements and circularelements. This combination of line elements and circular elements yieldsmore variation in localized stress to the fibrous structure ply sincethe geometry is more variable.

The thermal bond pattern in the resulting multi-ply fibrousstructure-containing article is the result of which HDE rolls is used inthe thermal bond process.

The use of continuous line elements can significantly alter the materialproperties of the resulting multi-ply fibrous structure-containingarticles after exposure to the HDTB process. Thermally bonded multi-plyfibrous structure-containing articles exhibit a very different VerticalFull Sheet (VFS) absorbency because water meets resistance as itattempts to flow out of the multi-ply fibrous structure-containingarticle when compared to the non-thermally bonded/non-water-resistantbonded multi-ply fibrous structure-containing articles which containareas of low resistance to the flow of water out of the multi-plyfibrous structure-containing article. Thermal bonds resist water flowsince the thermal bonded portion of the multi-ply fibrousstructure-containing article has very low pore volume.

NON-LIMITING EXAMPLES OF FIBROUS STRUCTURES OF THE PRESENT INVENTIONExample 1 Direct Formed—2-Ply Fibrous Structure-Containing Article

A 2-ply multi-ply fibrous structure-containing article is formed bycombining two direct formed fibrous structure plies 78, 80, which may bethe same or different from one another, as described below. Two rolls ofdirect formed fibrous structure plies 78, 80 are made as shown in FIG.6B where a co-formed fibrous structure ply 28 (co-formed fibrousstructure web associated with one meltblown fibrous structure web on onesurface of the co-formed fibrous structure web and a wet-laid fibrousstructure web 26 (a mono-fibrous element fibrous structure web)), forexample a textured wet-laid fibrous structure web, such as a 3Dpatterned wet-laid fibrous structure web on the opposite surface of theco-formed fibrous structure web. The wet-laid fibrous structure web 26may be further associated with a meltblown fibrous structure web on thewet-laid fibrous structure web's surface opposite the co-formed fibrousstructure ply 28. Each direct formed fibrous structure ply isconsolidated on a ElectroTech F541-28I forming fabric (commerciallyavailable from Albany International, Rochester, N.H.) and has 1.6 gsmpolypropylene filaments on a surface of a 10.8 gsm (3.5 gsmpolypropylene filaments and 7.3 gsm wood pulp fibers) co-formed fibrousstructure web, which is formed on a 16.6 gsm wet-laid, wet-texturedfibrous structure web 26, and 1.0 gsm polypropylene filaments on theother surface of the wet-laid, wet-textured fibrous structure web 26.The meltblown filaments of the meltblown fibrous structure web arecomprised of 48% LynondellBasell MF650x, 28% LynondellBasell MF650w, 17%LyondellBasell PH835, 5% Polyvel S1416, and 2% Ampacet 412951 and arespun from a multi-row capillary Biax-Fiberfilm die (Biax-FiberfilmCorporation, Greenville, Wis.) at a mass flow of 28 g/min and a ghm of0.22 and is attenuated with 16.4 kg/min of 204° C. (400° F.) air. Anexample of this process is shown in FIG. 2B.

Then, 440 grams per minute of Koch Industries 4725 semi-treated SSK arefed into a hammer mill and individualized into cellulose pulp fibers,which are pneumatically conveyed into a coforming box, example of whichis described in U.S. patent application Ser. No. 14/970,586 filed Dec.16, 2015, which is incorporated herein by reference. In the coformingbox, the pulp fibers are commingled with meltblown filaments. Themeltblown filaments are comprised of a blend of 48% LynondellBasellMF650x, 28% LynondellBasell MF650w, 17% LyondellBasell PH835, 5% PolyvelS1416, and 2% Ampacet 412951. The meltblown filaments are extruded/spunfrom a multi-row capillary Biax-Fiberfilm die at a ghm of 0.19 and atotal mass flow of 93.48 g/min. The meltblown filaments are attenuatedwith 14 kg/min of about 204° C. (400° F.) air. The mixture (commingled)cellulose pulp fibers and synthetic meltblown filaments are then laid ontop of the already formed 1.0 gsm of meltblown fibrous structure. Anexample of this process is shown in FIG. 2B. Next, a 1.6 gsm meltblownfibrous structure of the same composition as the meltblown fibrousstructure at 0.22 ghm and is attenuated with 16.4 kg/min of 204° C.(400° F.) air is laid down on top of the co-formed fibrous structuresuch that the co-formed fibrous structure is positioned between thefirst meltblown fibrous structure and the second meltblown fibrousstructure forming a multi-fibrous structure.

Two “parent” rolls of each direct formed fibrous structure ply areplaced on unwind stands and unwound while tensioning in such a mannerthat the fibrous structure plies are neither overly strained to causeexcessive fibrous structure ply neckdown nor under strained to causewrinkles or edge defects. This tension is maintained throughout theprocess by using a series of driven rolls and idlers. One unwoundfibrous structure ply (first fibrous structure ply) is metered to anemboss unit as described herein, for example a high definition emboss(HDE) unit, and drawn through the HDE unit's HDE nip, which is comprisedof two mated steel rolls that have 0.120″ tall metal protrusions. Thedesign of these protrusions is such that the surface of the rolls caninterfere without the protrusions touching each other until they bottomout with a 0.120″ interference. The first fibrous structure ply, whenpassed through the HDE nip, is sufficiently strained due to theinterference, spacing and number of the protrusions, to impart asignificant increase in caliper to the thickness of the first fibrousstructure ply and retains the general shape of the protrusions. Thefirst fibrous structure ply exits the HDE nip while adhering to theprotrusions on one of the two steel rolls that formed the HDE nip. Thefirst fibrous structure ply is then combined on the same steel rollwhile adhered to the protrusions with a second fibrous structure plythat does not pass through an HDE nip and that is unwound and tensionedas previously described with regard to the first fibrous structure ply.The second fibrous structure ply bypasses the HDE nip and is thencombined with the first fibrous structure ply with the use of a thirdroll that creates a thermal bond nip with the steel roll the firstfibrous structure ply is adhered to, when pressed with sufficient forceand heated to a certain temperature, causes the first and second fibrousstructure plies to bond sufficiently together, while the first fibrousstructure ply is adhered to the steel roll. The third roll is a smoothmetal roll, which is heated to result in a water-resistant bond 74, forexample a thermal bond, being formed between the first and secondfibrous structure plies at numerous areas, which creates void volumesbetween the fibrous structure plies. The interference between the matedsteel rolls forming the HDE nip is about 0.110″. All three of the rollsare run with a target surface temperature of about 240° F.-250° F. Thepressure run between in the thermal bond nip is about 150 pli. Withoutwishing to be bound by theory, it is believed that the combination oftemperature and pressure softens the polymer filaments and allows thepolymer to flow around the wet-laid fibrous web and forms a bond as itcools and sets. After exiting the thermal bond nip, the 2-ply fibrousstructure is now a consolidated 2-ply fibrous structure, which istensioned using driven rolls and idlers, that neither over strain the2-ply fibrous structure to cause excessive neckdown, nor under strainthe 2-ply fibrous structure to cause web handling control issues. The2-ply fibrous structure is then perforated to a 5.9″ sheet length usingrotating anvil and blade rolls and finally wound to a 5.8″ targetdiameter at 87 sheets using a rotating mandrel. FIG. 30 is an example ofa multi-ply fibrous structure-containing article made according to thisExample 1.

Example 2 Non-Direct Formed—4-Ply Fibrous Structure-containing Article

A 4-ply multi-ply fibrous structure-containing article comprising 2fibrous structure plies comprising co-formed fibrous structure plies 28and 2 fibrous structure plies comprising wet-laid fibrous structure webs26, any of which may be the same or different from one another, is madeas follows. Each co-formed fibrous structure ply 28 is consolidated on aVelostat170pc740 belt (commercially available from Albany International,Rochester, N.H.) traveling at 240 ft/min. and has 1.6 gsm polypropylenefilaments on a surface of a 10.8 gsm (3.5 gsm polypropylene filamentsand 7.3 gsm wood pulp fibers) co-formed fibrous structure web, and 1.0gsm polypropylene filaments on the other surface of the co-formedfibrous structure web to make the co-formed fibrous structure ply 28.Each wet-laid fibrous structure ply and/or web 26 is wet-textured and is16.6 gsm. The meltblown filaments of the meltblown fibrous structure arecomprised of 48% LynondellBasell MF650x, 28% LynondellBasell MF650w, 17%LyondellBasell PH835, 5% Polyvel S1416, and 2% Ampacet 412951 and arespun from a multi-row capillary Biax-Fiberfilm die (Biax-FiberfilmCorporation, Greenville, Wis.) at a mass flow of 28 g/min and a ghm of0.22 and is attenuated with 16.4 kg/min of 204° C. (400° F.) air. Anexample of this process is shown in FIG. 2B.

Then, 440 grams per minute of Koch Industries 4725 semi-treated SSK arefed into a hammer mill and individualized into cellulose pulp fibers,which are pneumatically conveyed into a coforming box, example of whichis described in U.S. patent application Ser. No. 14/970,586 filed Dec.16, 2015, which is incorporated herein by reference. In the coformingbox, the pulp fibers are commingled with meltblown filaments. Themeltblown filaments are comprised of a blend of 48% LynondellBasellMF650x, 28% LynondellBasell MF650w, 17% LyondellBasell PH835, 5% PolyvelS1416, and 2% Ampacet 412951. The meltblown filaments are extruded/spunfrom a multi-row capillary Biax-Fiberfilm die at a ghm of 0.19 and atotal mass flow of 93.48 g/min. The meltblown filaments are attenuatedwith 14 kg/min of about 204° C. (400° F.) air. The mixture (commingled)cellulose pulp fibers and synthetic meltblown filaments are then laid ontop of the already formed 1.0 gsm of meltblown fibrous structure. Anexample of this process is shown in FIG. 2B. Next, a 1.6 gsm meltblownfibrous structure of the same composition as the meltblown fibrousstructure at 0.22 ghm and is attenuated with 16.4 kg/min of 204° C.(400° F.) air is laid down on top of the co-formed fibrous structuresuch that the co-formed fibrous structure is positioned between thefirst meltblown fibrous structure and the second meltblown fibrousstructure forming a multi-fibrous structure.

One wet-laid fibrous structure ply is combined with one co-formedfibrous structure ply forming a first 2-ply fibrous structure and passedthrough an HDE unit's HDE nip, which is comprised of two mated steelrolls that have 0.120″ tall metal protrusions. The design of theseprotrusions is such that the surface of the rolls can interfere withoutthe protrusions touching each other until they bottom out with a 0.120″interference. The first 2-ply fibrous structure, when passed through theHDE nip, is sufficiently strained due to the interference, spacing andnumber of the protrusions, to impart a significant increase in caliperto the thickness of the first 2-ply fibrous structure and retains thegeneral shape of the protrusions. The first 2-ply fibrous structureexits the HDE nip while adhering to the protrusions on one of the twosteel rolls that formed the HDE nip. The first 2-ply fibrous structureis then combined on the same steel roll while adhered to the protrusionswith a second 2-ply fibrous structure (a co-formed fibrous structure plycombined with a wet-laid fibrous structure ply) that does not passthrough an HDE nip and that is unwound and tensioned as previouslydescribed with regard to the first 2-ply fibrous structure. The second2-ply fibrous structure bypasses the HDE nip and is then combined withthe first 2-ply fibrous structure with the use of a third roll thatcreates a thermal bond nip with the steel roll the first 2-ply fibrousstructure is adhered to, when pressed with sufficient force and heatedto a certain temperature, causes the first and second 2-ply fibrousstructures to bond sufficiently together, while the first 2-ply fibrousstructure is adhered to the steel roll. The third roll is a smooth metalroll, which is heated to result in a water-resistant bond 74, forexample a thermal bond, being formed between the first and second 2-plyfibrous structures at numerous areas, which creates void volumes betweenthe fibrous structure plies. The interference between the mated steelrolls forming the HDE nip is about 0.110″. All three of the rolls arerun with a target surface temperature of about 240° F.-250° F. Thepressure run between in the thermal bond nip is about 150 pli. Withoutwishing to be bound by theory, it is believed that the combination oftemperature and pressure softens the polymer filaments and allows thepolymer to flow around the wet-laid fibrous web and forms a bond as itcools and sets. After exiting the thermal bond nip, the 4-ply fibrousstructure is now a consolidated 4-ply fibrous structure, which istensioned using driven rolls and idlers, that neither over strain the4-ply fibrous structure to cause excessive neckdown, nor under strainthe 4-ply fibrous structure to cause web handling control issues. The4-ply fibrous structure is then perforated to a 5.9″ sheet length usingrotating anvil and blade rolls and finally wound to a 5.8″ targetdiameter at 87 sheets using a rotating mandrel. FIG. 31 is an example ofa multi-ply fibrous structure-containing article made according to thisExample 2.

Example 3 Direct Formed—2-Ply Fibrous Structure-containing Article

A 2-ply multi-ply fibrous structure-containing article is formed bycombining two direct formed fibrous structure plies as described below.Two rolls of direct formed fibrous structure plies are made as shown inFIG. 6B where a co-formed fibrous structure ply 28 (a co-formed fibrousstructure web associated with one meltblown fibrous structure web on onesurface of the co-formed fibrous structure web and a wet-laid fibrousstructure web 26 (a mono-fibrous element fibrous structure web)), forexample a textured wet-laid fibrous structure web, such as a 3Dpatterned wet-laid fibrous structure web on the opposite surface of theco-formed fibrous structure web. The wet-laid fibrous structure web 26may be further associated with a meltblown fibrous structure web(mono-fibrous element fibrous structure web) on the wet-laid fibrousstructure web's surface opposite the co-formed fibrous structure web.Each direct formed fibrous structure ply is consolidated on a texturedforming fabric and has 1.6 gsm polypropylene filaments on a surface of a8.0 gsm (2.0 gsm polypropylene filaments and 6.0 gsm wood pulp fibers)co-formed fibrous structure web, which is formed on a 21.0 gsm wet-laid,wet-textured fibrous structure web 26, and then after consolidation, 2.0gsm polypropylene filaments is applied to the other surface of thewet-laid, wet-textured fibrous structure web 26. The meltblown filamentsof the meltblown fibrous structure web are comprised of 48%LynondellBasell MF650x, 28% LynondellBasell MF650w, 17% LyondellBasellPH835, 5% Polyvel S1416, and 2% Ampacet 412951 and are spun from amulti-row capillary Biax-Fiberfilm die (Biax-Fiberfilm Corporation,Greenville, Wis.) at a mass flow of 28 g/min and a ghm of 0.22 and isattenuated with 16.4 kg/min of 204° C. (400° F.) air. An example of thisprocess is shown in FIG. 2B.

Then, 440 grams per minute of Koch Industries 4725 semi-treated SSK arefed into a hammer mill and individualized into cellulose pulp fibers,which are pneumatically conveyed into a coforming box, example of whichis described in U.S. patent application Ser. No. 14/970,586 filed Dec.16, 2015, which is incorporated herein by reference. In the coformingbox, the pulp fibers are commingled with meltblown filaments. Themeltblown filaments are comprised of a blend of 48% LynondellBasellMF650x, 28% LynondellBasell MF650w, 17% LyondellBasell PH835, 5% PolyvelS1416, and 2% Ampacet 412951. The meltblown filaments are extruded/spunfrom a multi-row capillary Biax-Fiberfilm die at a ghm of 0.19 and atotal mass flow of 93.48 g/min. The meltblown filaments are attenuatedwith 14 kg/min of about 204° C. (400° F.) air. The mixture (commingled)cellulose pulp fibers and synthetic meltblown filaments are then laid ontop of the already formed 1.0 gsm of meltblown fibrous structure. Anexample of this process is shown in FIG. 2B. Next, a 1.6 gsm meltblownfibrous structure of the same composition as the meltblown fibrousstructure at 0.22 ghm and is attenuated with 16.4 kg/min of 204° C.(400° F.) air is laid down on top of the co-formed fibrous structuresuch that the co-formed fibrous structure is positioned between thefirst meltblown fibrous structure and the second meltblown fibrousstructure forming a multi-fibrous structure.

Two “parent” rolls of each direct formed fibrous structure ply areplaced on unwind stands and unwound while tensioning in such a mannerthat the fibrous structure plies are neither overly strained to causeexcessive fibrous structure ply neckdown nor under strained to causewrinkles or edge defects. This tension is maintained throughout theprocess by using a series of driven rolls and idlers. One unwoundfibrous structure ply (first fibrous structure ply) is metered to a highdefinition emboss (HDE) unit and drawn through the HDE unit's HDE nip,which is comprised of two mated steel rolls that have 0.120″ tall metalprotrusions. The design of these protrusions is such that the surface ofthe rolls can interfere without the protrusions touching each otheruntil they bottom out with a 0.120″ interference. The first fibrousstructure ply, when passed through the HDE nip, is sufficiently straineddue to the interference, spacing and number of the protrusions, toimpart a significant increase in caliper to the thickness of the firstfibrous structure ply and retains the general shape of the protrusions.The first fibrous structure ply exits the HDE nip while adhering to theprotrusions on one of the two steel rolls that formed the HDE nip. Thefirst fibrous structure ply is then combined on the same steel rollwhile adhered to the protrusions with a second fibrous structure plythat does not pass through an HDE nip and that is unwound and tensionedas previously described with regard to the first fibrous structure ply.The second fibrous structure ply bypasses the HDE nip and is thencombined with the first fibrous structure ply with the use of a thirdroll that creates a thermal bond nip with the steel roll the firstfibrous structure ply is adhered to, when pressed with sufficient forceand heated to a certain temperature, causes the first and second fibrousstructure plies to bond sufficiently together, while the first fibrousstructure ply is adhered to the steel roll. The third roll is a smoothmetal roll, which is heated to result in a water-resistant bond 74, forexample a thermal bond, being formed between the first and secondfibrous structure plies at numerous areas, which creates void volumesbetween the fibrous structure plies. The interference between the matedsteel rolls forming the HDE nip is about 0.110″. All three of the rollsare run with a target surface temperature of about 240° F.-250° F. Thepressure run between in the thermal bond nip is about 150 pli. Withoutwishing to be bound by theory, it is believed that the combination oftemperature and pressure softens the polymer filaments and allows thepolymer to flow around the wet-laid fibrous web and forms a bond as itcools and sets. After exiting the thermal bond nip, the 2-ply fibrousstructure is now a consolidated 2-ply fibrous structure, which istensioned using driven rolls and idlers, that neither over strain the2-ply fibrous structure to cause excessive neckdown, nor under strainthe 2-ply fibrous structure to cause web handling control issues. The2-ply fibrous structure is then perforated to a 5.9″ sheet length usingrotating anvil and blade rolls and finally wound to a 5.8″ targetdiameter at 87 sheets using a rotating mandrel. FIG. 32 is an example ofa multi-ply fibrous structure-containing article made according to thisExample 3.

Example 4 Direct Formed—2-Ply Fibrous Structure-Containing Article

A 2-ply multi-ply fibrous structure-containing article is formed bycombining one direct formed fibrous structure ply (combination ofco-formed fibrous structure web and wet-laid fibrous structure web 26)as generally described above in Example 1 and one wet-laid fibrousstructure ply and/or web 26, wherein the wet-laid fibrous structure web26 of the direct formed fibrous structure ply may be the same ordifferent from the other wet-laid fibrous structure ply and/or web 26. Aroll of direct formed fibrous structure ply is made as shown in FIG. 6Bwhere a co-formed fibrous structure ply 28 comprising a co-formedfibrous structure web associated with one meltblown fibrous structureweb on one surface of the co-formed fibrous structure web and a wet-laidfibrous structure web 26 (a mono-fibrous element fibrous structure), forexample a textured wet-laid fibrous structure web, such as a 3Dpatterned wet-laid fibrous structure web on the opposite surface of theco-formed fibrous structure web. The wet-laid fibrous structure web 26may be further associated with a meltblown fibrous structure web on thewet-laid fibrous structure web's surface opposite the co-formed fibrousstructure web. The direct formed fibrous structure ply is consolidatedon a textured forming fabric and has 1.6 gsm polypropylene filaments ona surface of a 8.0 gsm (2.0 gsm polypropylene filaments and 6.0 gsm woodpulp fibers) co-formed fibrous structure web, which is formed on a 21.0gsm wet-laid, wet-textured fibrous structure web 26, and then afterconsolidation, 2.0 gsm polypropylene filaments is applied to the othersurface of the wet-laid, wet-textured fibrous structure web 26. Thewet-laid fibrous structure web 26 is wet-textured and is 28.0 gsm. Themeltblown filaments of the meltblown fibrous structure web are comprisedof 48% LynondellBasell MF650x, 28% LynondellBasell MF650w, 17%LyondellBasell PH835, 5% Polyvel S1416, and 2% Ampacet 412951 and arespun from a multi-row capillary Biax-Fiberfilm die (Biax-FiberfilmCorporation, Greenville, Wis.) at a mass flow of 28 g/min and a ghm of0.22 and is attenuated with 16.4 kg/min of 204° C. (400° F.) air. Anexample of this process is shown in FIG. 2B.

Then, 440 grams per minute of Koch Industries 4725 semi-treated SSK arefed into a hammer mill and individualized into cellulose pulp fibers,which are pneumatically conveyed into a coforming box, example of whichis described in U.S. patent application Ser. No. 14/970,586 filed Dec.16, 2015, which is incorporated herein by reference. In the coformingbox, the pulp fibers are commingled with meltblown filaments. Themeltblown filaments are comprised of a blend of 48% LynondellBasellMF650x, 28% LynondellBasell MF650w, 17% LyondellBasell PH835, 5% PolyvelS1416, and 2% Ampacet 412951. The meltblown filaments are extruded/spunfrom a multi-row capillary Biax-Fiberfilm die at a ghm of 0.19 and atotal mass flow of 93.48 g/min. The meltblown filaments are attenuatedwith 14 kg/min of about 204° C. (400° F.) air. The mixture (commingled)cellulose pulp fibers and synthetic meltblown filaments are then laid ontop of the already formed 1.0 gsm of meltblown fibrous structure. Anexample of this process is shown in FIG. 2B. Next, a 1.6 gsm meltblownfibrous structure of the same composition as the meltblown fibrousstructure at 0.22 ghm and is attenuated with 16.4 kg/min of 204° C.(400° F.) air is laid down on top of the co-formed fibrous structuresuch that the co-formed fibrous structure is positioned between thefirst meltblown fibrous structure and the second meltblown fibrousstructure forming a multi-fibrous structure.

A roll of direct formed fibrous structure ply and a roll of wet-laidfibrous structure ply and/or web 26 are placed on unwind stands andunwound while tensioning in such a manner that the fibrous structureplies are neither overly strained to cause excessive fibrous structureply neckdown nor under strained to cause wrinkles or edge defects. Thistension is maintained throughout the process by using a series of drivenrolls and idlers. A first fibrous structure ply (direct formed fibrousstructure ply) is metered to a high definition emboss (HDE) unit anddrawn through the HDE unit's HDE nip, which is comprised of two matedsteel rolls that have 0.120″ tall metal protrusions. The design of theseprotrusions is such that the surface of the rolls can interfere withoutthe protrusions touching each other until they bottom out with a 0.120″interference. The first fibrous structure ply, when passed through theHDE nip, is sufficiently strained due to the interference, spacing andnumber of the protrusions, to impart a significant increase in caliperto the thickness of the first fibrous structure ply and retains thegeneral shape of the protrusions. The first fibrous structure ply exitsthe HDE nip while adhering to the protrusions on one of the two steelrolls that formed the HDE nip. The first fibrous structure ply is thencombined on the same steel roll while adhered to the protrusions with asecond fibrous structure ply (the wet-laid fibrous structure ply) thatdoes not pass through an HDE nip and that is unwound and tensioned aspreviously described with regard to the first fibrous structure ply. Thesecond fibrous structure ply bypasses the HDE nip and is then combinedwith the first fibrous structure ply with the use of a third roll thatcreates a thermal bond nip with the steel roll the first fibrousstructure ply is adhered to, when pressed with sufficient force andheated to a certain temperature, causes the first and second fibrousstructure plies to bond sufficiently together, while the first fibrousstructure ply is adhered to the steel roll. The third roll is a smoothmetal roll, which is heated to result in a water-resistant bond 74, forexample a thermal bond, being formed between the first and secondfibrous structure plies at numerous areas, which creates void volumesbetween the fibrous structure plies. The interference between the matedsteel rolls forming the HDE nip is about 0.110″. All three of the rollsare run with a target surface temperature of about 240° F.-250° F. Thepressure run between in the thermal bond nip is about 150 pli. Withoutwishing to be bound by theory, it is believed that the combination oftemperature and pressure softens the polymer filaments and allows thepolymer to flow around the wet-laid fibrous web and forms a bond as itcools and sets. After exiting the thermal bond nip, the 2-ply fibrousstructure is now a consolidated 2-ply fibrous structure, which istensioned using driven rolls and idlers, that neither over strain the2-ply fibrous structure to cause excessive neckdown, nor under strainthe 2-ply fibrous structure to cause web handling control issues. The2-ply fibrous structure is then perforated to a 5.9″ sheet length usingrotating anvil and blade rolls and finally wound to a 5.8″ targetdiameter at 87 sheets using a rotating mandrel. FIG. 33 is an example ofa multi-ply fibrous structure-containing article made according to thisExample 4.

Example 5 Non-Co-formed—2-Ply Fibrous Structure-containing Article

A 28.0 gsm wet-laid fibrous structure ply or wet-laid fibrous web whichis made on a continuous knuckle/discrete pillow molding member with a25% knuckle area is unwound onto a patterned molding member, knucklesfacing away from the patterned molding member, traveling at 220ft/minute.

Next, a 2.0 gsm meltblown fibrous structure web (meltblown filaments) islaid down upon the wet-laid fibrous web 26. The meltblown filaments ofthe meltblown fibrous structure web are comprised of 48% LynondellBasellMF650x, 28% LynondellBasell MF650w, 17% LyondellBasell PH835, 5% PolyvelS1416, and 2% Ampacet 412951 and are spun from a multi-row capillaryBiax-Fiberfilm die (Biax-Fiberfilm Corporation, Greenville, Wis.) at amass flow of 28 g/min and a ghm of 0.22 and is attenuated with 16.4kg/min of 204° C. (400° F.) air. An example of this process is shown inFIG. 2B.

Next, a 2.0 gsm meltblown fibrous structure web of the same compositionas above at a ghm of 0.22 and attenuated with 16.4 kg/min of 204° C.(400° F.) air is laid down on the other side of the wet-laid fibrousweb. This multi-layer fibrous structure is then consolidated on aVelostat170pc740 belt (commercially available from Albany International,Rochester, N.H.) to form a non-co-formed fibrous structure.

Two rolls of this non-co-formed fibrous structure, which may be the sameor different from one another, are placed on unwind stands and unwoundwhile tensioning in such a manner that the non-co-formed fibrousstructure plies are neither overly strained to cause excessive fibrousstructure ply neckdown nor under strained to cause wrinkles or edgedefects. This tension is maintained throughout the process by using aseries of driven rolls and idlers. A first non-co-formed fibrousstructure ply is metered to a high definition emboss (HDE) unit anddrawn through the HDE unit's HDE nip, which is comprised of two matedsteel rolls that have 0.120″ tall metal protrusions. The design of theseprotrusions is such that the surface of the rolls can interfere withoutthe protrusions touching each other until they bottom out with a 0.120″interference. The first fibrous structure ply, when passed through theHDE nip, is sufficiently strained due to the interference, spacing andnumber of the protrusions, to impart a significant increase in caliperto the thickness of the first fibrous structure ply and retains thegeneral shape of the protrusions. The first fibrous structure ply exitsthe HDE nip while adhering to the protrusions on one of the two steelrolls that formed the HDE nip. The first fibrous structure ply is thencombined on the same steel roll while adhered to the protrusions with asecond non-co-formed fibrous structure ply that does not pass through anHDE nip and that is unwound and tensioned as previously described withregard to the first fibrous structure ply. The second fibrous structureply bypasses the HDE nip and is then combined with the first fibrousstructure ply with the use of a third roll that creates a thermal bondnip with the steel roll the first fibrous structure ply is adhered to,when pressed with sufficient force and heated to a certain temperature,causes the first and second fibrous structure plies to bond sufficientlytogether, while the first fibrous structure ply is adhered to the steelroll. The third roll is a smooth metal roll, which is heated to resultin a water-resistant bond 74, for example a thermal bond, being formedbetween the first and second fibrous structure plies at numerous areas,which creates void volumes between the fibrous structure plies. Theinterference between the mated steel rolls forming the HDE nip is about0.110″. All three of the rolls are run with a target surface temperatureof about 240° F.-250° F. The pressure run between in the thermal bondnip is about 150 pli. Without wishing to be bound by theory, it isbelieved that the combination of temperature and pressure softens thepolymer filaments and allows the polymer to flow around the wet-laidfibrous web and forms a bond as it cools and sets. After exiting thethermal bond nip, the 2-ply fibrous structure is now a consolidated2-ply fibrous structure, which is tensioned using driven rolls andidlers, that neither over strain the 2-ply fibrous structure to causeexcessive neckdown, nor under strain the 2-ply fibrous structure tocause web handling control issues. The 2-ply fibrous structure is thenperforated to a 5.9″ sheet length using rotating anvil and blade rollsand finally wound to a 5.8″ target diameter at 87 sheets using arotating mandrel. FIG. 34 is an example of a multi-ply fibrousstructure-containing article made according to this Example 5.

Example 6 2-Ply Fibrous Structure-containing Article

A 24.0 gsm wet-laid fibrous structure ply/web 26 is produced as follows.A cellulosic pulp fiber furnish consisting of about 63% refined softwoodfurnish consisting of about 76% Northern Bleached Softwood Kraft(Resolute), and 24% Southern Bleached Softwood Kraft (Alabama RiverSoftwood); 12% unrefined softwood furnish consisting of about 85%Northern Bleached Softwood Kraft (Resolute), and 15% Southern BleachedSoftwood Kraft (Alabama River Softwood); about 27% of unrefined hardwoodEucalyptus Bleached Kraft (Fibria); and 10% Co-PET/PET (2 Denier, 5 mmlength, Toray Chemical Korea). 0.9 ml Texcare SRN 240 (Clariant) isadded per pound of Co-PET/PET during re-pulping to enhance wettabilityof the synthetic fiber is made. Any further furnish preparation andrefining methodology common to the papermaking industry can be utilized.

A 3% active solution Kymene 5221 is added to the refined softwood lineprior to an in-line static mixer and 1% active solution of Wickit 1285,an ethoxylated fatty alcohol available from Ashland Inc. is added to theunrefined Eucalyptus Bleached Kraft (Fibria) hardwood furnish. Theaddition levels are 21 and 1 lbs active/ton of paper, respectively.

The refined softwood and unrefined hardwood and unrefinedNBSK/SSK/Eucalyptus bleached kraft/NDHK thick stocks are then blendedinto a single thick stock line followed by addition of 1% activecarboxymethylcellulose (CMC-CALEXIS) solution at 7 lbs active/ton ofpaper towel, and optionally, a softening agent may be added.

The thick stock is then diluted with white water at the inlet of a fanpump to a consistency of about 0.15% based on total weight of softwood,hardwood and simulated broke fiber. The diluted fiber slurry is directedto a non layered configuration headbox such that the wet web formed ontoa Fourdrinier wire (foraminous wire). Optionally, a finesretention/drainage aid may be added to the outlet of the fan pump.

Dewatering occurs through the Fourdrinier wire and is assisted bydeflector and vacuum boxes. The Fourdrinier wire is of a 5-shed, satinweave configuration having 87 machine-direction and 76 cross-directionmonofilaments per inch, respectively. The speed of the Fourdrinier wireis about 750 fpm (feet per minute).

The embryonic wet web is transferred from the Fourdrinier wire at afiber consistency of about 24% at the point of transfer, to a belt, suchas a patterned belt through-air-drying resin carrying fabric. In thepresent case, the speed of the patterned through-air-drying fabric isapproximately the same as the speed of the Fourdrinier wire. In anothercase, the embryonic wet web may be transferred to a patterned beltand/or fabric that is traveling slower, for example about 20% slowerthan the speed of the Fourdrinier wire (for example a wet moldingprocess).

Further de-watering is accomplished by vacuum assisted drainage untilthe web has a fiber consistency of about 30%.

While remaining in contact with the patterned belt, the web is pre-driedby air blow-through pre-dryers to a fiber consistency of about 65% byweight.

After the pre-dryers, the semi-dry web is transferred to a Yankee dryerand adhered to the surface of the Yankee dryer with a sprayed crepingadhesive. The creping adhesive is an aqueous dispersion with the activesconsisting of about 75% polyvinyl alcohol, and about 25% CREPETROL®R6390. Optionally a crepe aid consisting of CREPETROL® A3025 may beapplied. CREPETROL® R6390 and CREPETROL® A3025 are commerciallyavailable from Ashland Inc. (formerly Hercules Inc.). The crepingadhesive diluted to about 0.15% adhesive solids and delivered to theYankee surface at a rate of about 2 # adhesive solids based on the dryweight of the web. The fiber consistency is increased to about 97%before the web is dry creped from the Yankee with a doctor blade.

In the present case, the doctor blade has a bevel angle of about 45° andis positioned with respect to the Yankee dryer to provide an impactangle of about 101° and the reel is run at a speed that is about 15%faster than the speed of the Yankee. In another case, the doctor blademay have a bevel angle of about 25° and be positioned with respect tothe Yankee dryer to provide an impact angle of about 81° and the reel isrun at a speed that is about 7% faster than the speed of the Yankee. TheYankee dryer hood is operated at a temperature of about 450° F. and aspeed of about 700 fpm. In the pre-dryer and on the yankee the co-petsheath softens and forms thermoplastic bonds with cellulosic fiber inthe sheet

The fibrous structure is wound in a roll using a surface driven reeldrum having a surface speed of about 750 feet per minute.

One parent roll of the wet-laid fibrous structure ply/web 26 (firstfibrous structure ply) is unwound and metered to an emboss unit asdescribed herein, for example a high definition emboss (HDE) unit, anddrawn through the HDE unit's HDE nip, which is comprised of two matedsteel rolls that have 0.120″ tall metal protrusions. The design of theseprotrusions is such that the surface of the rolls can interfere withoutthe protrusions touching each other until they bottom out with a 0.120″interference. The first wet laid fibrous structure ply, when passedthrough the HDE nip, is sufficiently strained due to the interference,spacing and number of the protrusions, to impart a significant increasein caliper to the thickness of the first fibrous structure ply andretains the general shape of the protrusions. The first wet laid fibrousstructure ply exits the HDE nip while adhering to the protrusions on oneof the two steel rolls that formed the HDE nip. The first wet laidfibrous structure ply is then combined on the same steel roll whileadhered to the protrusions with a second wet laid fibrous structure plythat does not pass through an HDE nip and that is unwound and tensionedas previously described with regard to the first fibrous structure ply.The second wet laid fibrous structure ply bypasses the HDE nip and isthen combined with the first fibrous structure ply with the use of athird roll that creates a thermal bond nip with the steel roll the firstfibrous structure ply is adhered to, when pressed with sufficient forceand heated to a certain temperature, causes the first and second wetlaid fibrous structure plies to bond sufficiently together, while thefirst wet laid fibrous structure ply is adhered to the steel roll. Thethird roll is a smooth metal roll, which is heated to result in athermal bond 74, in this case a water-resistant bond, being formedbetween the first and second wet laid fibrous structure plies arenumerous areas. The interference between the mated steel rolls formingthe HDE nip is about 0.110″. All three of the rolls are run with atarget surface temperature of about 240° F.-250° F. The pressure runbetween in the thermal bond nip is about 150 pli. Without wishing to bebound by theory, it is believed that the combination of temperature andpressure softens the co-PET sheath and allows the polymer to flow aroundthe wet-laid fibrous web and forms a water-resistant bond 74, forexample a thermal bond, as it cools and sets. After exiting the thermalbond nip, the 2-ply fibrous structure is now a consolidated 2-plyfibrous structure, which is tensioned using driven rolls and idlers,that neither over strain the 2-ply fibrous structure to cause excessiveneckdown, nor under strain the 2-ply fibrous structure to cause webhandling control issues. The 2-ply fibrous structure is then perforatedto a 5.9″ sheet length using rotating anvil and blade rolls and finallywound to a 5.8″ target diameter at 87 sheets using a rotating mandrel.FIG. 34 is an example of a multi-ply fibrous structure-containingarticle made according to this Example 6.

Test Methods

Unless otherwise specified, all tests described herein including thosedescribed under the Definitions section and the following test methodsare conducted on samples that have been conditioned in a conditionedroom at a temperature of 23° C.±1.0° C. and a relative humidity of50%±2% for a minimum of 24 hours prior to the test. All plastic andpaper board packaging articles of manufacture, if any, must be carefullyremoved from the samples prior to testing. The samples tested are“usable units.” “Usable units” as used herein means sheets, flats fromroll stock, pre-converted flats, fibrous structure, and/or single ormulti-ply products. Except where noted all tests are conducted in suchconditioned room, all tests are conducted under the same environmentalconditions and in such conditioned room. Discard any damaged product. Donot test samples that have defects such as wrinkles, tears, holes, andlike. All instruments are calibrated according to manufacturer'sspecifications.

Hand Protection Test Method

A single useable unit, for example from a roll of multi-ply fibrousstructure-containing articles (for example a paper towel roll) is placedbetween two pieces of impermeable material that have a rectangular10″×5″ hole and clamped into place. The towel is oriented so the 10″dimension is in the CD and the 5″ dimension is in the MD as shown inFIG. 35. The holder with the multi-ply fibrous structure-containingarticle in it is then placed with the side of the multi-ply fibrousstructure-containing article towards the outside of the roll facingupwards and normal to the force of gravity. Optionally, the side of thetowel facing the inside of the roll could be facing up. The towel isplaced a holder and is held on a frame that is situated approximately 6″above the top surface of the scale. A bucket (catch basin) is placed onthe scale to catch the water as it passes through the multi-ply fibrousstructure article (towel in this example).

As shown in FIG. 36, a 3/16″ ID tube is placed such that the dischargeof the tube is horizontal and located just above the top surface of thetowel, approximately 1″ from one MD edge and in the center of the CDdimension. The tube is oriented so that the discharge of the water is inthe MD direction. At the beginning of the test, water is pumped at 5mL/sec 0.25 mL/sec onto the top of the towel. A timer starts when waterhits the top of the sheet and the scale begins outputting weight every0.1 seconds. Data is collected in a text file for analysis.

At the beginning of the test a blank with no sample in the holder isrun. Time is started when water leaves the 3/16″ ID tube and stoppedwhen 0.15 g of water is collected in the bucket. This “blank time” willthen be subtracted from the total time collected for the towel sampleexperiments, as this is a function of the experimental geometry and notthe towel.

The value that is reported is the time, reported to the nearest 0.01seconds, that takes 0.15 grams of water to pass through the towel andinto the bucket, minus the blank time, keeping track of which side ofthe towel was facing up. Both sides should be tested, with the time to0.15 grams of water reported for each side separately. Three replicatesare ran per side, averaged, and reported as one instance, or “N”.

Surface Texture Analysis Test Method

In the Surface Texture Analysis Test Method, sheets of a fibrousstructure are removed from an article, such as a paper towel roll, andthe areal surface topology of both sides are measured using opticalprofilometry. The 3D surface data are then processed and analyzed toextract the Core Height Value, Core Height Difference Value, Core VoidVolume, and Core Material Volume. All sample preparation and testing isperformed in a conditioned room maintained at about 23±2° C. and about50±2% relative humidity, and samples are equilibrated in thisenvironment for at least 24 hours prior to testing.

Sample Preparation

Test samples are usable unit sheets removed from three differentlocations within the article, such as the outside, middle, and inside ofa paper towel roll. Two replicate usable unit samples are removed ateach of the three locations, maximizing the amount of distance betweenthe three locations within the article, while avoiding sheets withnoticeable defects. Each sample's location and side, outward or inwardfacing within the roll, should be identified and noted.

3D Surface Image Acquisition

Three-dimensional (3D) surface topography images are obtained oncorresponding outer facing and inner facing sides of a sample using anoptical 3D surface topography measurement system (a suitable optical 3Dsurface topography measurement system is the MikroCAD Premium instrumentcommercially available from LMI Technologies Inc., Vancouver, Canada, orequivalent). The system includes the following main components: a) aDigital Light Processing (DLP) projector with direct digital controlledmicro-mirrors; b) a CCD camera with at least a 1600×1200 pixelresolution; c) projection optics adapted to a measuring area of at least140 mm×105 mm; d) recording optics adapted to a measuring area of 140mm×105 mm; e) a table tripod based on a small hard stone plate; f) ablue LED light source; g) a measuring, control, and evaluation computerrunning surface texture analysis software (a suitable software isMikroCAD software with MountainsMap technology, or equivalent); and h)calibration plates for lateral (xy) and vertical (z) calibrationavailable from the vendor.

The optical 3D surface topography measurement system measures thesurface height of a sample using the digital micro-mirror pattern fringeprojection technique. The result of the measurement is a 3D image ofsurface height (defined as the or z axis) versus displacement in thehorizontal (xy) plane. The system has a field of view of 140×105 mm withan xy pixel resolution of approximately 85 microns. The heightresolution is set at 0.5 micron/count, with a height range of +/−16 mm.

The instrument is calibrated according to manufacturer's specificationsusing the calibration plates for lateral (xy plane) and vertical (zaxis) available from the vendor.

The sample placed flat on the table beneath the camera. A 3D surfacetopology image of the specimen is collected by following the instrumentmanufacturer's recommended measurement procedures, which may includefocusing the measurement system and performing a brightness adjustment.No pre-filtering options are used. The collected height image file issaved to the evaluation computer running the surface texture analysissoftware.

3D Surface Image Analysis

The 3D surface topography image is opened in the surface textureanalysis software. The following filtering procedure is then performedon each image: 1) removal of invalid, or non-measured, points; 2) a 3×3pixel median filter to remove noise; 3) remove by subtraction the leastsquare plane to level the surface; and 4) a Gaussian filter (accordingto ISO 16610-61) with a nesting index (cut-off wavelength) of 25 mm toflatten the surface. End effect correction is not utilized such that theimage size is reduced by half of the cut-off wavelength around theperimeter.

This filtering procedure produces the S-L surface from which the arealsurface texture parameters will be calculated. For each of the 3Dsurface topography images of both sides of the two replicate samplesfrom the three locations, the following analysis is then performed.

The Core Height Value and Core Height Difference Value measurements arebased on the core height, Sk, parameter described in ISO 13565-2:1996standard extrapolated to surfaces and ISO 25178-2:2012. The parameter Skis derived from the Areal Material Ratio (Abbott-Firestone) curve, whichis the cumulative curve of the surface height distribution histogramversus the range of surface heights. The Core Height Value is the heightdifference between the material ratios Mr1 and Mr2 as read off of theAreal Material Ratio curve. Mr1, set to 2%, is the material ratio whichseparates the protruding peaks from the core roughness region. Mr2, setto 98%, is the material ratio which separates the deep valleys from thecore roughness region. Record the Core Height Value to the nearest 0.01mm. The Core Height Difference Value is the absolute value differencebetween the Core Height Values measured on the outward and inward facingsurfaces of a usable unit sample. Record the Core Height Differencevalue to the nearest 0.01 mm.

The Core Void Volume (Vvc) and Core Material Volume (Vmc) measurementsare described in ISO 25178-2:2012. The Vvc and Vmc parameters arederived from the Areal Material Ratio (Abbott-Firestone) curve describedin the ISO 13565-2:1996 standard extrapolated to surfaces, which is thecumulative curve of the surface height distribution histogram versus therange of surface heights. A material ratio is the ratio, given as a %,of the intersecting area of a plane passing through the surface at agiven height to the cross sectional area of the evaluation region. Vvcis the difference in void volume between p and q material ratios, andVmc is the difference in material volume between p and q materialratios. The Core Void Volume is the volume of void space above thesurface of the sample between the height corresponding to a materialratio value of 2% to the material ratio of 98%, which is the Vvcparameter calculated with a p value of 2% and q value of 98%. The CoreMaterial Volume is the volume of material below the surface of thesample between the height corresponding to a material ratio value of 2%to the material ratio of 98%, which is the Vmc parameter calculated witha p value of 2% and q value of 98%. The volumes are normalized to thearea (volume/area) of the image and are recorded to the nearest 0.001mm³/mm².

Reporting of Method Parameters

After the analysis described above in the 3D surface image analysissection is performed on 3D surface topology images of all five specimenreplicates, the following output parameters are defined and reported.

The arithmetic mean of the two replicate Core Height Values measured oneach side of a sample at the three different roll locations iscalculated and is reported to the nearest 0.01 mm. The arithmetic meanof the two replicate Core Height Difference Values measured at the threedifferent roll locations is calculated and is reported to the nearest0.01 mm. The arithmetic mean of the two replicate Core Void Volume (Vvc)values measured on each side of a sample at the three different rolllocations is calculated and is reported to the nearest 0.001 mm³/mm².The arithmetic mean of the two replicate Core Material Volume (Vmc)values measured on each side of a sample at the three different rolllocations is calculated and is reported to the nearest 0.001 mm³/mm².

Horizontal Full Sheet (HFS) Test Method

The Horizontal Full Sheet (HFS) test method determines the amount ofdistilled water absorbed and retained by a fibrous structure of thepresent invention. This method is performed by first weighing a sampleof the fibrous structure to be tested (referred to herein as the “dryweight of the sample”), then thoroughly wetting the sample, draining thewetted sample in a horizontal position and then reweighing (referred toherein as “wet weight of the sample”). The absorptive capacity of thesample is then computed as the amount of water retained in units ofgrams of water absorbed by the sample. When evaluating different fibrousstructure samples, the same size of fibrous structure is used for allsamples tested.

The apparatus for determining the HFS capacity of fibrous structurescomprises the following:

1) An electronic balance with a sensitivity of at least ±0.01 grams anda minimum capacity of 1200 grams. The balance should be positioned on abalance table and slab to minimize the vibration effects offloor/benchtop weighing. The balance should also have a special balancepan to be able to handle the size of the sample tested (i.e.; a fibrousstructure sample of about 11 in. (27.9 cm) by 11 in. (27.9 cm)). Thebalance pan can be made out of a variety of materials. Plexiglass is acommon material used.

2) A sample support rack (FIGS. 41, 41A) and sample support rack cover(FIGS. 42, 42A) is also required. Both the rack and cover are comprisedof a lightweight metal frame, strung with 0.012 in. (0.305 cm) diametermonofilament so as to form a grid as shown in FIGS. 41, 41A. The size ofthe support rack and cover is such that the sample size can beconveniently placed between the two.

The HFS test is performed in an environment maintained at 23±1° C. and50±2% relative humidity. A water reservoir or tub is filled withdistilled water at 23±1° C. to a depth of 3 inches (7.6 cm).

Eight samples of a fibrous structure to be tested are carefully weighedon the balance to the nearest 0.01 grams. The dry weight of each sampleis reported to the nearest 0.01 grams. The empty sample support rack isplaced on the balance with the special balance pan described above. Thebalance is then zeroed (tared). One sample is carefully placed on thesample support rack. The support rack cover is placed on top of thesupport rack. The sample (now sandwiched between the rack and cover) issubmerged in the water reservoir. After the sample is submerged for 60seconds, the sample support rack and cover are gently raised out of thereservoir.

The sample, support rack and cover are allowed to drain horizontally for120±5 seconds, taking care not to excessively shake or vibrate thesample. While the sample is draining, the rack cover is carefullyremoved and all excess water is wiped from the support rack. The wetsample and the support rack are weighed on the previously tared balance.The weight is recorded to the nearest 0.01 g. This is the wet weight ofthe sample.

The gram per fibrous structure sample absorptive capacity of the sampleis defined as (wet weight of the sample—dry weight of the sample). Thehorizontal absorbent capacity (HAC) is defined as: absorbentcapacity=(wet weight of the sample—dry weight of the sample)/(dry weightof the sample) and has a unit of gram/gram.

Vertical Full Sheet (VFS) Test Method

The Vertical Full Sheet (VFS) test method determines the amount ofdistilled water absorbed and retained by a fibrous structure of thepresent invention. This method is performed by first weighing a sampleof the fibrous structure to be tested (referred to herein as the “dryweight of the sample”), then thoroughly wetting the sample, draining thewetted sample in a vertical position and then reweighing (referred toherein as “wet weight of the sample”). The absorptive capacity of thesample is then computed as the amount of water retained in units ofgrams of water absorbed by the sample. When evaluating different fibrousstructure samples, the same size of fibrous structure is used for allsamples tested.

The apparatus for determining the VFS capacity of fibrous structurescomprises the following:

1) An electronic balance with a sensitivity of at least ±0.01 grams anda minimum capacity of 1200 grams. The balance should be positioned on abalance table and slab to minimize the vibration effects offloor/benchtop weighing. The balance should also have a special balancepan to be able to handle the size of the sample tested (i.e.; a fibrousstructure sample of about 11 in. (27.9 cm) by 11 in. (27.9 cm)). Thebalance pan can be made out of a variety of materials. Plexiglass is acommon material used.

2) A sample support rack (FIGS. 41, 41A) and sample support rack cover(FIGS. 42, 42A) is also required. Both the rack and cover are comprisedof a lightweight metal frame, strung with 0.012 in. (0.305 cm) diametermonofilament so as to form a grid as shown in FIGS. 41, 41A. The size ofthe support rack and cover is such that the sample size can beconveniently placed between the two.

The VFS test is performed in an environment maintained at 23±1° C. and50±2% relative humidity. A water reservoir or tub is filled withdistilled water at 23±1° C. to a depth of 3 inches (7.6 cm).

Eight 19.05 cm (7.5 inch)×19.05 cm (7.5 inch) to 27.94 cm (11inch)×27.94 cm (11 inch) samples of a fibrous structure to be tested arecarefully weighed on the balance to the nearest 0.01 grams. The dryweight of each sample is reported to the nearest 0.01 grams. The emptysample support rack is placed on the balance with the special balancepan described above. The balance is then zeroed (tared). One sample iscarefully placed on the sample support rack. The support rack cover isplaced on top of the support rack. The sample (now sandwiched betweenthe rack and cover) is submerged in the water reservoir. After thesample is submerged for 60 seconds, the sample support rack and coverare gently raised out of the reservoir.

The sample, support rack and cover are allowed to drain vertically for60±5 seconds, taking care not to excessively shake or vibrate thesample. While the sample is draining, the rack cover is carefullyremoved and all excess water is wiped from the support rack. The wetsample and the support rack are weighed on the previously tared balance.The weight is recorded to the nearest 0.01 g. This is the wet weight ofthe sample.

The procedure is repeated for with another sample of the fibrousstructure, however, the sample is positioned on the support rack suchthat the sample is rotated 90° compared to the position of the firstsample on the support rack.

The gram per fibrous structure sample absorptive capacity of the sampleis defined as (wet weight of the sample−dry weight of the sample). Thecalculated VFS is the average of the absorptive capacities of the twosamples of the fibrous structure.

Roll Firmness Test Method

Roll Firmness is measured on a constant rate of extension tensile testerwith computer interface (a suitable instrument is the MTS Alliance usingTestworks 4.0 Software, as available from MTS Systems Corp., EdenPrairie, Minn.) using a load cell for which the forces measured arewithin 10% to 90% of the limit of the cell. The roll product is heldhorizontally, a cylindrical probe is pressed into the test roll, and thecompressive force is measured versus the depth of penetration. Alltesting is performed in a conditioned room maintained at 23° C.±2 C. °and 50%±2% relative humidity.

Referring to FIG. 39 below, the upper movable fixture 1000 consist of acylindrical probe 1001 made of machined aluminum with a 19.00±0.05 mmdiameter and a length of 38 mm. The end of the cylindrical probe 1002 ishemispheric (radius of 9.50±0.05 mm) with the opposing end 1003 machinedto fit the crosshead of the tensile tester. The fixture includes alocking collar 1004 to stabilize the probe and maintain alignmentorthogonal to the lower fixture. The lower stationary fixture 1100 is analuminum fork with vertical prongs 1101 that supports a smooth aluminumsample shaft 1101 in a horizontal position perpendicular to the probe.The lower fixture has a vertical post 1102 machined to fit its base ofthe tensile tester and also uses a locking collar 1103 to stabilize thefixture orthogonal to the upper fixture.

The sample shaft 1101 has a diameter that is 85% to 95% of the innerdiameter of the roll and longer than the width of the roll. The ends ofsample shaft are secured on the vertical prongs with a screw cap 1104 toprevent rotation of the shaft during testing. The height of the verticalprongs 1101 should be sufficient to assure that the test roll does notcontact the horizontal base of the fork during testing. The horizontaldistance between the prongs must exceed the length of the test roll.

Program the tensile tester to perform a compression test, collectingforce and crosshead extension data at an acquisition rate of 100 Hz.Lower the crosshead at a rate of 10 mm/min until 5.00 g is detected atthe load cell. Set the current crosshead position as the corrected gagelength and zero the crosshead position. Begin data collection and lowerthe crosshead at a rate of 50 mm/min until the force reaches 10 N.Return the crosshead to the original gage length.

Remove all of the test rolls from their packaging and allow them tocondition at about 23° C.±2° C. and about 50%±2% relative humidity for 2hours prior to testing. Rolls with cores that are crushed, bent ordamaged should not be tested. Insert sample shaft through the testroll's core and then mount the roll and shaft onto the lower stationaryfixture. Secure the sample shaft to the vertical prongs then align themidpoint of the roll's width with the probe. Orient the test roll's tailseal so that it faces upward toward the probe. Rotate the roll 90degrees toward the operator to align it for the initial compression.

Position the tip of the probe approximately 2 cm above the surface ofthe sample roll. Zero the crosshead position and load cell and start thetensile program. After the crosshead has returned to its startingposition, rotate the roll toward the operator 120 degrees and in likefashion acquire a second measurement on the same sample roll.

From the resulting Force (N) verses Distance (mm) curves, read at thedata point closest to 7.00 N as the Roll Firmness and record to thenearest 0.1 mm. In like fashion analyze a total of ten (10) replicatesample rolls. Calculate the arithmetic mean of the 20 values and reportRoll Firmness to the nearest 0.1 mm.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm.”

Every document cited herein, including any cross referenced or relatedpatent or application and any patent application or patent to which thisapplication claims priority or benefit thereof, is hereby incorporatedherein by reference in its entirety unless expressly excluded orotherwise limited. The citation of any document is not an admission thatit is prior art with respect to any invention disclosed or claimedherein or that it alone, or in any combination with any other referenceor references, teaches, suggests or discloses any such invention.Further, to the extent that any meaning or definition of a term in thisdocument conflicts with any meaning or definition of the same term in adocument incorporated by reference, the meaning or definition assignedto that term in this document shall govern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. A process for making a multi-ply fibrousstructure-containing article, the process comprising the steps of: a.embossing a fibrous structure ply by passing the fibrous structure plythrough a high definition emboss nip such that the resulting multi-plyfibrous structure-containing article exhibits a Core Height Value ofgreater than 0.60 mm as measured according to the Surface TextureAnalysis Test Method to form an embossed fibrous structure plycomprising an embossment; and b. bonding the emboss fibrous structureply with at least one other fibrous structure ply by a water-resistantbond separate from the embossment of the embossed fibrous structure plyto form a multi-ply fibrous structure-containing article, wherein voidvolume exists between the bonded fibrous structure plies of themulti-ply fibrous structure-containing article.
 2. The process accordingto claim 1 wherein the multi-ply fibrous structure-containing articlecomprises a plurality of fibrous elements.
 3. The process according toclaim 2 wherein the fibrous elements comprise a plurality of filaments.4. The article according to claim 2 wherein the fibrous elementscomprise a plurality of fibers.
 5. The article according to claim 2wherein the fibrous elements comprises a plurality of fibers andfilaments commingled together.
 6. The process according to claim 1wherein the embossed fibrous structure ply is a co-formed fibrousstructure ply.
 7. The process according to claim 1 wherein the embossedfibrous structure ply is a wet-laid fibrous structure ply.
 8. Theprocess according to claim 1 wherein the wet-laid fibrous structure plycomprises pulp fibers and synthetic staple fibers.
 9. The processaccording to claim 1 wherein the embossed fibrous structure ply is adirect formed fibrous structure ply.
 10. The process according to claim1 wherein the other fibrous structure ply is a co-formed fibrousstructure ply.
 11. The process according to claim 1 wherein the otherfibrous structure ply is a wet-laid fibrous structure ply.
 12. Theprocess according to claim 1 wherein the wet-laid fibrous structure plycomprises pulp fibers and synthetic staple fibers.
 13. The processaccording to claim 1 wherein the other fibrous structure ply is a directformed fibrous structure ply.
 14. The process according to claim 1wherein the multi-ply fibrous structure-containing article exhibits aCore Height Difference Value of greater than 0.50 mm as measuredaccording to the Surface Texture Analysis Test Method.
 15. The processaccording to claim 1 wherein the other fibrous structure ply is anon-embossed fibrous structure ply.
 16. The process according to claim 1wherein the high definition emboss nip comprises a high definitionemboss roll having an emboss element having a height of greater than0.60 mm.
 17. The process according to claim 1 wherein the step ofbonding comprising passing the embossed fibrous structure ply and otherfibrous structure ply through a bonding nip.
 18. The process accordingto claim 17 wherein the bonding nip comprises a thermal bond roll. 19.The process according to claim 1 wherein the water-resistant bondcomprises a thermal bond.
 20. The process according to claim 1 whereinthe water-resistant bond comprises a water-resistant adhesive bond.